Direct biochar cooling methods and systems

ABSTRACT

Apparatus and associated methods relate to cooling hot biochar based on applying cool gas directly to the hot biochar. The gas may be steam comprising water vapor. Biochar may be cooled in a cooling chamber by cool steam injected into a steam loop configured to cool the steam. The biochar cooled with steam may be dried in a drying chamber by dry gas injected from a gas loop. The gas may be hydrocarbon gas. Biochar may be heated in a processing chamber. Heated biochar may be cooled in a cooling chamber by cool hydrocarbon gas injected to the cooling chamber. Biochar in the processing chamber may be heated with heat recovered from cooling. Filtered byproducts and tail gas may be recovered from the cooling chamber. Tail gas may be recycled. Various direct biochar cooling implementations may produce biochar having enhanced carbon content, increased surface area, and a hydrogen stream byproduct.

TECHNICAL FIELD

This disclosure relates generally to biochar cooling.

BACKGROUND

Decarbonization of the energy sector is a topic of importance to avoidirreversible global warming. Hydrogen has been considered as an optionto replace fossil fuels in industrial, residential, and transportapplications. However, hydrogen production has been almost limited tothe reforming of hydrocarbons. Reforming hydrocarbons may release largeamounts of CO₂, thus requiring several downstream purificationprocesses.

Gasification is a thermal decomposition process in which solid organicor carbonaceous materials (feedstock) may break down into a combustiblegas mixture. The combustible gas components formed are primarily carbonmonoxide (CO), hydrogen (H₂), and methane (CH₄). Other non-combustiblegases such as nitrogen (N₂), steam (H₂O), and carbon dioxide (CO₂) mayalso be present in various quantities. The process of gasification mayinvolve pyrolysis followed by partial oxidation, which may be controlledby injecting air or other oxygen containing gases into the partiallypyrolyzed feedstock. More specifically, biomass gasification may be asequence of reactions including water evaporation, lignin decomposition,cellulosic deflagration and carbon reduction. An external heat sourcemay begin the reaction, but partial oxidation may provide heat tomaintain the thermal decomposition of the feedstock. If concentratedoxygen is used, the resulting gas mixture may be called syngas. If air(which includes nitrogen) is used as the oxidant, the resulting gasmixture may be called producer gas. For simplicity, the term “ProducerGas” as used herein shall include both syngas and producer gas. Both gasmixtures are considered a “fuel gas” and can be used as a replacementfor natural gas in some processes. They can also be used as a precursorto generate various industrial chemicals and motor fuels. When biomassis used as the feedstock, gasification and combustion of the ProducerGas is considered to be a source of renewable energy.

As a general matter, gasification offers a more efficient, costeffective and environmentally friendly alternative for extractingpotential energy from solid feedstock as compared to combustion. As aresult of gasification, the feedstock's potential energy can beconverted to Producer Gas, which is cleaner burning, compressible andmore portable. Producer Gas may be burned directly in some engines andburners, purified to produce methanol and hydrogen, or converted via theFischer-Tropsch and other methods and processes into synthetic liquidfuel.

In general, biomass gasification is the thermochemical conversion oforganic (waste) feedstock in a high-temperature environment, throughwhich biomass may be converted not only to syngas for energy generationbut also to chemicals, for instance, methane, ethylene, adhesives, fattyacids, surfactants, detergents, and plasticizers. A byproduct of biomassgasification is hot biochar.

The present disclosure relates to direct cooling of biochar resultingfrom gasification by downdraft and fluidized bed gasifiers. Briefdowndraft and fluidized bed gasification descriptions and simpleexamples of downdraft and fluidized bed gasifiers are provided.Exemplary downdraft gasification may be implemented using downdraftgasification techniques disclosed with reference to FIGS. 1-21 of U.S.Pat. No. 10,662,386 by Kelfkens, et al., filed on Dec. 6, 2019 as U.S.patent application Ser. No. 16/705,837, and entitled “Method forgasifying feedstock with high yield production of biochar,” the entirecontents of which are herein incorporated by reference. Exemplaryfluidized bed gasification may be implemented using fluidized bedgasification techniques disclosed with reference to FIGS. 1-8 of U.S.Pat. No. 10,696,913 by Kelfkens, et al., filed on Dec. 20, 2019 as U.S.patent application Ser. No. 16/723,538, and entitled “Gasificationreactor with pipe distributor,” the entire contents of which are hereinincorporated by reference.

Downdraft Gasification

In downdraft gasification, all feedstock, air and gases flow in the samedirection—from top to bottom. Although updraft gasification is typicallyfavored for processing of biomass feedstock and fluid bed gasificationis typically used in gasification of coal, downdraft gasificationprocess has a number of advantages. One advantage of downdraftgasification is low levels of tar in the resulting Producer Gas becausethe tars generated during pyrolysis must pass through the Oxidation Zoneand the char bed in the Reduction Zone before exiting the gasifier. Thehigh temperature of the Oxidation Zone and the top of the char bedbreaks down the tars (i.e., thermal cracking). The result is a ProducerGas that may be cooled and more easily cleaned for use in reciprocatingengines, gas-fired turbines and catalytic reforming processes.

In an exemplary downdraft gasifier implementation, there may be threezones: a Pyrolysis Zone, an Oxidation Zone and a Reduction Zone. In sucha gasifier, (1) the residence time of feedstock could be controlled inthe Oxidation Zone (relative to the flow of feedstock through the restof the gasifier) to allow the maximum amount of feedstock to undergogasification before passing out of the Oxidation Zone into the ReductionZone and (2) the Reduction Zone would be designed to cause the hot gasproduced in the Oxidation Zone to mix with the char in the ReductionZone as quickly and as thoroughly as possible to promote thoroughgasification.

Fluidized-Bed Gasification

In an exemplary fluidized-bed gasifier implementation, oxidant may beblown through a bed of solid particles at a sufficient velocity to keepthe solid particles in a state of suspension. The feedstock isintroduced to the gasifier, very quickly mixed with the bed material andalmost instantaneously heated to the bed temperature either externallyor using a heat transfer medium. Most of these fluidized-bed gasifiersare equipped with an internal cyclone in order to minimize char (carriedover into the Producer Gas stream) and remove fluidizing media from theProducer Gas. The major advantages include feedstock flexibility and theability to easily control the reaction temperature, which allows forgasification of fine grained materials (sawdust, etc.) without the needof pre-processing. Fluidized-bed gasifiers also scale very well to largesizes.

In various exemplary gasification scenarios, hot carbonaceous residuemay come off or through the grate of a downdraft gasifier, off thebottom of a cyclone, or off the bottom of a cyclone in association witha fluidized bed gasifier. Both downdraft and fluidized bed gasifiersystems may employ an expensive indirect cooling approach to create acool biochar that may not be resizable (Grinder) based on product demandby a gasifier system using indirect cooling.

Some prior art biochar cooling implementations may indirectly utilizeheated steam to run over biochar to improve the biochar's compositionalcharacteristics. These prior art biochar cooling processes may heatsteam to extremely high temperatures to react with ambient temperaturebiochar. Some prior art biochar cooling implementations may indirectlyutilize heated hydrocarbon gas run over biochar to improve compositionalcharacteristics and decompose methane. These prior art biochar coolingprocesses may heat hydrocarbon gas streams to extremely hightemperatures to react with the ambient temperature biochar.

In an illustrative example, the composition of biochar product from agasifier employing indirect cooling may not be useful in high valueapplications, such as, for example, as an alternative to activatedcarbon. In addition, the biochar product from a gasifier employingindirect cooling may not be useful in production of high purity carbonfor manufacturing purposes, such as, for example, graphene.

SUMMARY

Apparatus and associated methods relate to cooling hot biochar based onapplying cool gas directly to the hot biochar. The gas may be steamcomprising water vapor. Biochar may be cooled in a cooling chamber bycool steam injected into a steam loop configured to cool the steam. Thebiochar cooled with steam may be dried in a drying chamber by dry gasinjected from a gas loop. The gas may be hydrocarbon gas. Biochar may beheated in a processing chamber. Heated biochar may be cooled in acooling chamber by cool hydrocarbon gas injected to the cooling chamber.Biochar in the processing chamber may be heated with heat recovered fromcooling. Filtered byproducts and tail gas may be recovered from thecooling chamber. Tail gas may be recycled. Various direct biocharcooling implementations may produce biochar having enhanced carboncontent, increased surface area, and a hydrogen stream byproduct.

In an aspect, an apparatus may comprise: a cooling chamber; a steam loopconfigured to be fluidly coupled with the cooling chamber; a dryingchamber configured to be fluidly coupled with the cooling chamber; a gasloop configured to be fluidly coupled with the drying chamber; and acontrol system configured to cause the apparatus to perform operationscomprising: inject cool steam from the steam loop into the coolingchamber; apply the cool steam directly to hot biochar retained withinthe cooling chamber; and in response to a determination the biocharretained within the cooling chamber cooled to a predeterminedtemperature: discharge the cooled biochar into the drying chamber;inject dry gas from the gas loop into the drying chamber; and inresponse to a determination the biochar retained within the dryingchamber dried to a predetermined moisture level, discharge the cooleddried biochar from the drying chamber.

The apparatus may further comprise the cooling chamber configured toreceive hot biochar via at least one discharge valve configured to befluidly coupled with the cooling chamber.

The operations performed by the apparatus may further comprise receivehot biochar into the cooling chamber via at least one discharge valvefluidly coupled with the cooling chamber.

Receive hot biochar may further comprise receive hot biochar from agasifier fluidly coupled with the apparatus.

The gasifier may further comprise a downdraft gasifier.

The gasifier may further comprise a fluidized bed gasifier.

The steam loop may further comprise a heat exchanger.

The gas loop may further comprise a particulate filter.

The apparatus may further comprise at least one discharge valveconfigured to fluidly couple the cooling chamber to the drying chamber.

In an implementation, an apparatus may comprise: a cooling chamber; atleast one discharge valve configured to be fluidly coupled with thecooling chamber, wherein the at least one discharge valve is configuredto be fluidly coupled with a gasifier to direct hot biochar from thegasifier into the cooling chamber; a steam loop configured to be fluidlycoupled with the cooling chamber, wherein the steam loop is configuredwith a steam particulate filter and a heat exchanger; a drying chamberconfigured to be fluidly coupled with the cooling chamber by at leastone discharge valve configured to direct biochar from the coolingchamber into the drying chamber; a gas loop configured to be fluidlycoupled with the drying chamber, wherein the gas loop is configured witha gas particulate filter and a heat exchanger; at least one dischargevalve configured to be fluidly coupled with the drying chamber, whereinthe at least one discharge valve is configured to release biochar fromthe drying chamber; and a control system configured to cause theapparatus to perform operations comprising: receive hot biochar from thegasifier into the cooling chamber; inject cool steam from the steam loopinto the cooling chamber; apply the cool steam directly to the hotbiochar retained within the cooling chamber; and in response to adetermination the biochar retained within the cooling chamber cooled toa predetermined temperature: discharge the cooled biochar into thedrying chamber; inject dry gas from the gas loop into the dryingchamber; and in response to a determination the biochar retained withinthe drying chamber dried to a predetermined moisture level, release thecooled dried biochar from the drying chamber.

The gasifier may further comprise a downdraft gasifier.

The gasifier may further comprise a fluidized bed gasifier.

The cooling chamber may be fluidly coupled with the gasifier.

The steam particulate filter may further comprise a ceramic filter.

The gas particulate filter may further comprise a sintered metal filter.

The apparatus may further comprise stainless steel.

In an implementation, an apparatus may comprise: a cooling chamberconfigured with a gas inlet, a biochar inlet, a biochar outlet, and agas outlet; at least one discharge valve configured to be fluidlycoupled with the cooling chamber biochar inlet, wherein the at least onedischarge valve is configured to be fluidly coupled with a gasifier todirect hot biochar from the gasifier into the cooling chamber; a steamloop configured to be fluidly coupled with the cooling chamber gas inletand the cooling chamber gas outlet, wherein the steam loop comprises asteam makeup port fluidly coupled with the steam loop; a steamparticulate filter configured with an inlet and a filtered outlet,wherein the steam particulate filter inlet is fluidly coupled with thecooling chamber gas outlet, and wherein the steam particulate filteroutlet is fluidly coupled with the steam loop; a heat exchangerconfigured in the steam loop, wherein the heat exchanger comprises asteam to liquid heat exchanger; a drying chamber configured with a gasinlet, a biochar inlet, a biochar outlet, and a gas outlet, wherein thedrying chamber biochar inlet is configured to be fluidly coupled withthe cooling chamber biochar outlet by at least one discharge valveconfigured to direct biochar from the cooling chamber into the dryingchamber; a gas loop configured to be fluidly coupled with the dryingchamber gas inlet and the drying chamber gas outlet, wherein the gasloop comprises a gas makeup port fluidly coupled with the gas loop; agas particulate filter configured with an inlet and a filtered outlet,wherein the gas particulate filter inlet is fluidly coupled with thedrying chamber gas outlet, and wherein the gas particulate filter outletis fluidly coupled with the gas loop; a heat exchanger configured in thegas loop, wherein the heat exchanger comprises a gas to liquid or gas togas heat exchanger; and a control system configured to cause theapparatus to perform operations comprising: receive hot biochar from thegasifier into the cooling chamber; inject cool steam from the steam loopinto the cooling chamber gas inlet; apply the cool steam directly to hotbiochar retained within the cooling chamber; and in response to adetermination the biochar retained within the cooling chamber cooled toa predetermined temperature: discharge the cooled biochar into thedrying chamber; inject dry gas from the gas loop into the dryingchamber; and in response to a determination the biochar retained withinthe drying chamber dried to a predetermined moisture level, release thecooled dried biochar from the drying chamber.

The apparatus may further comprise a biochar recovery system fluidlycoupled with the drying chamber biochar outlet, and wherein release thecooled dried biochar from the drying chamber further comprises releasethe cooled dried biochar into the biochar recovery system.

The operations performed by the apparatus may further comprise injectcool steam into the steam loop steam makeup port.

The operations performed by the apparatus may further comprise injectdry gas into the gas loop gas makeup port.

In another aspect, an apparatus may comprise: a processing chamber; aheat source thermally coupled with the processing chamber; a coolingchamber configured to be fluidly coupled with the processing chamber;and a control system configured to cause the apparatus to performoperations comprising: heat biochar retained within the processingchamber; and in response to a determination the biochar retained withinthe processing chamber heated to a predetermined temperature: dischargethe hot biochar into the cooling chamber; inject cool gas into thecooling chamber; apply the cool gas directly to the hot biochar retainedwithin the cooling chamber; and in response to a determination thebiochar retained within the cooling chamber cooled to a predeterminedtemperature, discharge the cooled biochar from the cooling chamber.

The processing chamber may be configured to receive biochar via at leastone discharge valve configured to be fluidly coupled with the processingchamber.

The operations performed by the apparatus may further comprise receivebiochar into the processing chamber via at least one discharge valvefluidly coupled with the processing chamber.

Receive biochar may further comprise receive biochar from a gasifierfluidly coupled with the apparatus.

The gasifier may further comprise a downdraft gasifier.

The gasifier may further comprise a fluidized bed gasifier.

The heat source may further comprise a heating element.

The heat source may further comprise process heat.

The apparatus may further comprise at least one discharge valveconfigured to fluidly couple the processing chamber to the coolingchamber.

In an implementation, an apparatus may comprise: a processing chamber;at least one discharge valve configured to be fluidly coupled with theprocessing chamber, wherein the at least one discharge valve isconfigured to be fluidly coupled with a gasifier to direct biochar fromthe gasifier into the processing chamber; a heat source thermallycoupled with the processing chamber, wherein the heat source comprises aheating element; a cooling chamber configured to be fluidly coupled withthe processing chamber by at least one discharge valve configured todirect biochar from the processing chamber into the cooling chamber,wherein the cooling chamber includes a gas inlet port, and wherein thecooling chamber includes a gas outlet configured to be fluidly coupledwith a particulate filter by a discharge valve; a CO₂ removal filterhaving an inlet, a CO₂ outlet, and a mixed gas outlet, wherein the CO₂removal filter inlet is fluidly coupled with the particulate filter; anH₂ removal filter having an inlet, an H₂ outlet, and a mixed gas outlet,wherein the H₂ removal filter inlet is fluidly coupled with the CO₂removal filter mixed gas outlet; at least one discharge valve configuredto be fluidly coupled with the cooling chamber, wherein the at least onedischarge valve is configured to release biochar from the coolingchamber; and a control system configured to cause the apparatus toperform operations comprising: heat biochar retained within theprocessing chamber, using the heat source; and in response to adetermination the biochar retained within the processing chamber heatedto a predetermined temperature: discharge the hot biochar into thecooling chamber; inject cool gas comprising hydrocarbon into the coolingchamber through the cooling chamber gas inlet port; apply the coolhydrocarbon gas directly to the hot biochar retained within the coolingchamber; and in response to a determination the biochar retained withinthe cooling chamber cooled to a predetermined temperature: release thecooled biochar from the cooling chamber; and release the hydrocarbon gasinto the particulate filter through the cooling chamber gas outlet.

The gasifier may further comprise a downdraft gasifier.

The gasifier may further comprise a fluidized bed gasifier.

The processing chamber may be fluidly coupled with the gasifier.

The apparatus may further comprise a thermal oxidizer thermally coupledwith the processing chamber, and a tail gas recycle loop fluidly coupledwith the H₂ removal filter mixed gas output and the thermal oxidizer.

The tail gas recycle loop may be fluidly coupled with the coolingchamber gas inlet port.

The apparatus may further comprise a biochar recovery system and theoperations performed by the apparatus further comprise release thecooled biochar into the biochar recovery system.

In an implementation, an apparatus may comprise: a processing chamber;at least one discharge valve configured to be fluidly coupled with theprocessing chamber, wherein the at least one discharge valve is fluidlycoupled with a gasifier to direct biochar from the gasifier into theprocessing chamber; a cooling chamber configured to be fluidly coupledwith the processing chamber by at least one discharge valve configuredto direct biochar from the processing chamber into the cooling chamber,wherein the cooling chamber includes a gas inlet port, and wherein thecooling chamber includes a gas outlet configured to be fluidly coupledwith a particulate filter by a discharge valve; a CO₂ removal filterhaving an inlet, a CO₂ outlet, and a mixed gas outlet, wherein the CO₂removal filter inlet is fluidly coupled with the particulate filter; anH₂ removal filter having an inlet, an H₂ outlet, and a mixed gas outlet,wherein the H₂ removal filter inlet is fluidly coupled with the CO₂removal filter mixed gas outlet; a thermal oxidizer thermally coupledwith the processing chamber, and a tail gas recycle loop fluidly coupledwith the H₂ removal filter mixed gas output and the thermal oxidizer,wherein the tail gas recycle loop is fluidly coupled with the coolingchamber gas inlet port; a heat source thermally coupled with theprocessing chamber, wherein the heat source comprises heat from thethermal oxidizer; at least one discharge valve configured to be fluidlycoupled with the cooling chamber, wherein the at least one dischargevalve is configured to release biochar from the cooling chamber; and acontrol system configured to cause the apparatus to perform operationscomprising: heat biochar retained within the processing chamber, usingthe heat source; and in response to a determination the biochar retainedwithin the processing chamber heated to a predetermined temperature:discharge the hot biochar into the cooling chamber; inject cool gascomprising hydrocarbon into the cooling chamber through the coolingchamber gas inlet port; apply the cool hydrocarbon gas directly to thehot biochar retained within the cooling chamber; in response to adetermination the biochar retained within the cooling chamber cooled toa predetermined temperature: release the cooled biochar from the coolingchamber; and release the hydrocarbon gas through the cooling chamber gasoutlet into the particulate filter.

The apparatus may further comprise a biochar recovery system and theoperations performed by the apparatus further comprise release thecooled biochar into the biochar recovery system.

The apparatus may further comprise a tail gas recovery system fluidlycoupled with the H₂ removal filter mixed gas outlet.

The apparatus may further comprise an H₂ gas recovery system fluidlycoupled with the H₂ removal filter H₂ outlet.

In an aspect, a method may comprise: injecting cool steam into a coolingchamber; applying the cool steam directly to hot biochar retained withinthe cooling chamber; and in response to a determining the biocharretained within the cooling chamber cooled to a predeterminedtemperature: discharging the cooled biochar into a drying chamber;injecting dry gas into the drying chamber; and in response todetermining the biochar retained within the drying chamber dried to apredetermined moisture level, discharging the cooled dried biochar fromthe drying chamber.

Injecting cool steam may further comprise injecting steam from a steamloop configured to cool steam.

The steam loop may further comprise a heat exchanger.

The method may further comprise receiving hot biochar into the coolingchamber.

Receiving hot biochar may further comprise receiving hot biochar from agasifier.

The gasifier may further comprise a downdraft gasifier.

The gasifier may further comprise a fluidized bed gasifier.

Injecting dry gas may further comprise injecting gas from a gas loopconfigured to dry gas.

The gas loop may further comprise a particulate filter and a heatexchanger.

In an implementation, a method may comprise: receiving hot biochar froma gasifier into a cooling chamber; injecting cool steam from a steamloop into the cooling chamber, wherein the steam loop is configured witha steam particulate filter and a heat exchanger comprising a heat sink;applying the cool steam directly to the hot biochar retained within thecooling chamber; and in response to determining the biochar retainedwithin the cooling chamber cooled to a predetermined temperature:discharging the cooled biochar into a drying chamber; injecting dry gasfrom a gas loop into the drying chamber, wherein the gas loop isconfigured with a gas particulate filter and a heat exchanger comprisinga heat sink; and in response to determining the biochar retained withinthe drying chamber dried to a predetermined moisture level, releasingthe cooled dried biochar from the drying chamber.

The gasifier may further comprise a downdraft gasifier.

The gasifier may further comprise a fluidized bed gasifier.

The steam particulate filter may further comprise a ceramic filter.

The steam particulate filter may further comprise a sintered metalfilter.

The gas particulate filter may further comprise a ceramic filter.

The gas particulate filter may further comprise a sintered metal filter.

In an implementation, a method may comprise: receiving hot biochar froma gasifier into a cooling chamber through a discharge valve; injectingcool steam from a steam loop into the cooling chamber; applying the coolsteam directly to hot biochar retained within the cooling chamber; andin response to determining, by a control system, the biochar retainedwithin the cooling chamber cooled to a predetermined temperature:discharging, by the control system, the cooled biochar through adischarge valve into a drying chamber; injecting dry gas from a gas loopinto the drying chamber; and in response to determining, by the controlsystem, the biochar retained within the drying chamber dried to apredetermined moisture level, releasing, by the control system, thecooled dried biochar from the drying chamber through a discharge valve.

Releasing the cooled dried biochar from the drying chamber may furthercomprise releasing the cooled dried biochar into a biochar recoverysystem.

The method may further comprise injecting cool steam into a steam makeupport fluidly coupled with the steam loop.

The method may further comprise injecting dry gas into a gas makeup portfluidly coupled with the gas loop.

In another aspect, a method may comprise: heating biochar retainedwithin a processing chamber, using a heat source thermally coupled withthe processing chamber; and in response to determining the biocharretained within the processing chamber heated to at least apredetermined temperature: discharging the heated biochar into a coolingchamber; injecting cool gas into the cooling chamber; applying the coolgas directly to the biochar retained within the cooling chamber; and inresponse to determining the biochar retained within the cooling chambercooled to a predetermined temperature, discharging the cooled biocharfrom the cooling chamber.

The method may further comprise receiving biochar into the processingchamber.

The method may further comprise receiving biochar from a gasifier intothe processing chamber, and retaining the biochar within the processingchamber.

The gasifier may further comprise a downdraft gasifier.

The gasifier may further comprise a fluidized bed gasifier.

The heat source may further comprise a heating element.

The heat source may further comprise process heat, and the method mayfurther comprise: in response to determining the process heat is atleast a predetermined minimum temperature, deactivating the heatingelement.

Discharging the heated biochar into the cooling chamber may furthercomprise fluidly coupling the processing chamber to the cooling chamber.

The method may further comprise retaining the biochar within theprocessing chamber for at least a predetermined time period.

In an implementation, a method may comprise: receiving biochar into aprocessing chamber configured to be fluidly coupled with a gasifier;heating the biochar retained within the processing chamber, using a heatsource thermally coupled with the processing chamber, wherein the heatsource comprises a heating element and process heat; and in response todetermining the biochar retained within the processing chamber heated toa predetermined temperature: discharging the heated biochar into acooling chamber; injecting cool gas comprising hydrocarbon into thecooling chamber; applying the cool gas comprising hydrocarbon directlyto the biochar retained within the cooling chamber; and in response todetermining the biochar retained within the cooling chamber cooled to apredetermined temperature: releasing the cooled biochar from the coolingchamber; and releasing gas from the cooling chamber into a particulatefilter fluidly coupled with the cooling chamber.

The gasifier may further comprise a downdraft gasifier.

The gasifier may further comprise a fluidized bed gasifier.

The gasifier may be fluidly coupled with the processing chamber.

The method may further comprise recovering carbon dioxide from a CO₂removal filter fluidly coupled with the particulate filter.

The method may further comprise recovering hydrogen from an H₂ removalfilter fluidly coupled with the particulate filter.

The method may further comprise recycling tail gas as cooling gassupplied to the cooling chamber through a tail gas recycle loop fluidlycoupled with the H₂ removal filter and the cooling chamber.

The method may further comprise heating the biochar retained within theprocessing chamber using process heat comprising heat generated by athermal oxidizer from tail gas, wherein the thermal oxidizer isthermally coupled with the processing chamber.

The method may further comprise supplying the tail gas to the thermaloxidizer from an H₂ removal filter fluidly coupled with the particulatefilter.

In an aspect, a method may comprise: receiving biochar from a gasifierinto a processing chamber; heating biochar retained within theprocessing chamber, using a heat source thermally coupled with theprocessing chamber, wherein the heat source comprises a heating elementand recovered process heat from a thermal oxidizer supplied with tailgas; in response to a determination, by a control system, the processheat is at least a predetermined minimum temperature, deactivating, bythe control system, the heating element; and in response to determining,by a control system, the biochar retained within the processing chamberheated to at least a predetermined minimum temperature: discharging thebiochar into a cooling chamber; injecting cool gas into the coolingchamber; applying the cool gas directly to the biochar retained withinthe cooling chamber; and in response to a determining, by the controlsystem, the biochar retained within the cooling chamber cooled to atleast a predetermined maximum temperature: releasing the biochar fromthe cooling chamber; releasing gas from the cooling chamber into aparticulate filter; recovering carbon dioxide from a CO₂ removal filterfluidly coupled with the particulate filter; recovering hydrogen from anH₂ removal filter fluidly coupled with the CO₂ removal filter; supplyingtail gas recovered from the H₂ removal filter to the thermal oxidizer;heating the processing chamber using process heat comprising heatgenerated by the thermal oxidizer from the tail gas; and recycling aportion of the tail gas as cooling gas supplied to the cooling chamber.

The method may further comprise repeating the method with the heatingelement deactivated.

The method may further comprise releasing the biochar from the coolingchamber into a biochar recovery system.

Receiving biochar from the gasifier may further comprise receivingbiochar from a plurality of gasifiers.

More than one gasifier of the plurality of gasifiers may be fluidlycoupled with the processing chamber.

A direct biochar cooling implementation in accordance with the presentdisclosure may provide an alternative to an indirect biochar coolingdesign.

Various implementations in accordance with the present disclosure relateto a cost-effective means to cool hot biochar using direct applicationof cool gases comprising H₂O or CH₄. An exemplary direct coolingimplementation in accordance with the present disclosure may decomposecooling gas comprising methane.

A co-effect of an exemplary direct cooling approach in accordance withthe present disclosure may be that the cool gases comprising compoundswhich include CH₄ decompose into carbon, which may aggregate asadditional solid carbon. Another co-effect may be that the physical andchemical composition of the biochar may be modified as a result of theapplication of the cooling gas, which may increase the surface area ofthe carbon and/or modify the carbon structures.

In one aspect of the present disclosure, direct cooling of hot biocharwith steam as the hot biochar exits a gasifier or cyclone may create aneconomical way to cool biochar while enhancing the surface area of thebiochar, resulting in a byproduct that is comparable to activatedcarbon.

In another aspect of the present disclosure, direct cooling of hotbiochar with hydrocarbon gas as the hot biochar exits the gasifier orcyclone may create an economical way to cool biochar while enhancing thehigh-quality carbon content of the biochar with nano tube type carbonformation on the biochar [chemical vapor deposition], while producing agas stream that may be filtered for high value chemical (such as, forexample, hydrogen) recovery.

In an illustrative example, various implementations in accordance withthe present disclosure may not use a formulated metal catalyst. To theextent metals are present in biochar produced by such implementationsthat do not use a formulated metal catalyst, the metals present in thebiochar may derive from the natural presence of the metals in thebiomass, or the metals' non-deliberate presence in the biosolids.

The present disclosure teaches direct biochar cooling.

Direct biochar cooling may be implemented as an apparatus. Directbiochar cooling may be implemented as a method.

The apparatus may comprise steam direct biochar cooling. The apparatusmay comprise hydrocarbon gas direct biochar cooling. The apparatus maycomprise hydrocarbon gas direct biochar cooling with tail gas recycling.

The steam direct biochar cooling apparatus comprises a cooling chamber.The steam direct biochar cooling apparatus comprises a drying chamberconfigured to be fluidly coupled with the cooling chamber. The coolingchamber comprises at least one inlet. The cooling chamber comprises atleast one outlet. The drying chamber comprises at least one inlet. Thedrying chamber comprises at least one outlet. The apparatus may comprisea discharge valve configured to fluidly couple the cooling chamber withthe drying chamber. The apparatus may comprise a flange configured to befluidly coupled with the cooling chamber. The cooling chamber may befluidly coupled with the flange by a discharge valve. The flange fluidlycoupled with the cooling chamber may be configured to be fluidly coupledwith a gasifier. The flange configured to be fluidly coupled with thegasifier may be fluidly coupled with the cooling chamber by a dischargevalve. The apparatus may comprise at least one feed mechanism configuredto be fluidly coupled with at least one discharge valve. The at leastone feed mechanism may be configured to be fluidly coupled with thecooling chamber. The at least one feed mechanism may be configured to befluidly coupled with the drying chamber. The apparatus comprises a steamloop fluidly coupled with the cooling chamber. The steam loop may befluidly coupled with at least one cooling chamber outlet. The steam loopmay be fluidly coupled with at least one cooling chamber inlet. Thesteam loop may comprise a particulate filter serially coupled with atleast one cooling chamber outlet and at least one cooling chamber inlet.The steam loop may comprise a heat exchanger serially coupled with atleast one cooling chamber outlet and at least one cooling chamber inlet.The heat exchanger may comprise a heat sink. The steam loop may comprisea steam inlet port. The apparatus comprises a gas loop fluidly coupledwith the drying chamber. The gas loop may be fluidly coupled with atleast one drying chamber outlet. The gas loop may be fluidly coupledwith at least one drying chamber inlet. The gas loop may comprise a heatexchanger serially coupled with at least one drying chamber outlet andat least one drying chamber inlet. The heat exchanger may comprise aheat sink. The gas loop may comprise a gas inlet port. The gas loop maycomprise a particulate filter serially coupled with at least one dryingchamber outlet and at least one drying chamber inlet. The apparatus maycomprise a flange configured to be fluidly coupled with the dryingchamber. The drying chamber may be fluidly coupled with the flange by adischarge valve. The flange fluidly coupled with the drying chamber maybe configured to be fluidly coupled with a biochar processing system.The apparatus may further comprise a control system configured to coolhot biochar. Cooling hot biochar may comprise operably couple one ormore discharge valve and one or more feed mechanism to receive hotbiochar in the cooling chamber, inject cool steam from the steam loopinto the cooling chamber to cool the hot biochar, retain the cool steamand biochar in the cooling chamber until the biochar is cooled to apredetermined temperature, direct the cooled biochar into the dryingchamber, inject dry gas from the gas loop into the drying chamber to drythe moist biochar, retain the dry gas and biochar in the drying chamberuntil the biochar is dried to a predetermined moisture level, anddischarge the dried cooled biochar from the drying chamber.

The hydrocarbon gas direct biochar cooling apparatus comprises aprocessing chamber. The hydrocarbon gas direct biochar cooling apparatuscomprises a cooling chamber configured to be fluidly coupled with theprocessing chamber. The processing chamber comprises at least one inlet.The processing chamber comprises at least one outlet. The coolingchamber comprises at least one inlet. The cooling chamber comprises atleast one outlet. The apparatus may comprise a discharge valveconfigured to fluidly couple the processing chamber with the coolingchamber. The apparatus may comprise a flange configured to be fluidlycoupled with the processing chamber. The processing chamber may befluidly coupled with the flange by a discharge valve. The flange fluidlycoupled with the processing chamber may be configured to be fluidlycoupled with a gasifier. The flange configured to be fluidly coupledwith the gasifier may be fluidly coupled with the processing chamber bya discharge valve. The apparatus may comprise at least one feedmechanism configured to be fluidly coupled with at least one dischargevalve. The at least one feed mechanism may be configured to be fluidlycoupled with the processing chamber. The at least one feed mechanism maybe configured to be fluidly coupled with the cooling chamber. Theapparatus may comprise a heating element thermally coupled with theprocessing chamber. The apparatus may comprise the processing chamberthermally coupled with process heat to receive heat from a gasificationprocess or from biochar cooling. The processing chamber may be thermallycoupled with a heat exchanger. The heat exchanger may comprise a heatsink. The heat exchanger may be configured to extract heat from exhaustgas. The heat exchanger may be configured to extract heat from thecooling chamber. The cooling chamber may comprise at least one gas inletport. The apparatus may comprise at least one cooling chamber outletcoupled with a particulate filter. The apparatus may comprise at leastone cooling chamber outlet coupled with a gas chromatograph. Theapparatus may comprise at least one cooling chamber outlet coupled witha CO₂ removal filter. The apparatus may comprise at least one coolingchamber outlet coupled with an H₂ removal filter. The particulate filtermay be serially coupled with the CO₂ removal filter. The particulatefilter may be serially coupled with the H₂ removal filter. The CO₂removal filter may be serially coupled with the H₂ removal filter. TheCO₂ removal filter may have a mixed gas outlet. The CO₂ removal filtermay have a CO₂ outlet. The H₂ removal filter may have a mixed gasoutlet. The CO₂ removal filter may have an H₂ outlet. The apparatus maycomprise a flange configured to be fluidly coupled with the coolingchamber. The cooling chamber may be fluidly coupled with the flange by adischarge valve. The flange fluidly coupled with the cooling chamber maybe configured to be fluidly coupled with a biochar processing system.The apparatus may comprise a tail gas recycle loop. The tail gas recycleloop may fluidly couple at least one cooling chamber gas inlet port withat least one removal filter mixed gas outlet. The at least one removalfilter mixed gas outlet coupled with the at least one cooling chambergas inlet port may be an H₂ removal filter mixed gas outlet. The removalfilter mixed gas outlet coupled with the at least one cooling chambergas inlet port may be a CO₂ removal filter mixed gas outlet. The tailgas recycle loop may fluidly couple at least one cooling chamber gasinlet port with at least one removal filter mixed gas outlet and athermal oxidizer. The thermal oxidizer may be thermally coupled with aheat exchanger that is configured to be thermally coupled with theprocessing chamber. The apparatus may further comprise a control systemconfigured to cool hot biochar. Cooling hot biochar may compriseoperably couple one or more discharge valve and one or more feedmechanism to receive hot biochar in the processing chamber, process thebiochar based on heating the biochar in the processing chamber, retainthe biochar in the processing chamber for a predetermined time or untilthe biochar reaches a predetermined temperature, direct the biochar inthe processing chamber into the cooling chamber, inject cool gas fromthe gas inlet port into the cooling chamber to cool the biochar, retainthe gas and biochar in the cooling chamber until the biochar is cooledto a predetermined temperature, and discharge the cooled biochar fromthe cooling chamber.

The method may comprise steam direct biochar cooling. The method maycomprise hydrocarbon gas direct biochar cooling. The method may comprisehydrocarbon gas direct biochar cooling with tail gas recycling.

The steam direct biochar cooling method may comprise receiving hotbiochar in a cooling chamber, injecting cool steam into the coolingchamber, retaining the cool steam and biochar in the cooling chamberuntil the biochar is cooled to a predetermined temperature, directingthe cooled biochar into the drying chamber, injecting dry gas into thedrying chamber, retaining the dry gas and biochar in the drying chamberuntil the biochar is dried to a predetermined moisture level, anddischarging the dried cooled biochar from the drying chamber. Receivinghot biochar in the cooling chamber may comprise operably coupling one ormore discharge valve and one or more feed mechanism to receive the hotbiochar. Injecting cool steam into the cooling chamber may compriseinjecting cool steam from the steam loop into the cooling chamber tocool the hot biochar. Injecting dry gas into the drying chamber maycomprise injecting dry gas from the gas loop into the drying chamber todry the moist biochar. Discharging the dried cooled biochar from thedrying chamber may comprise operably coupling one or more dischargevalve to discharge the dried cooled biochar.

The hydrocarbon gas direct biochar cooling method may comprise receivinghot biochar in a processing chamber, processing the biochar based onheating the biochar in the processing chamber, retaining the biochar inthe processing chamber until the biochar reaches a predeterminedtemperature, directing the biochar in the processing chamber into thecooling chamber, injecting cool gas into the cooling chamber to cool thebiochar, retaining the gas and biochar in the cooling chamber until thebiochar is cooled to a predetermined temperature, and discharging thecooled biochar from the cooling chamber. The method may compriseremoving CO₂ from gas directed from the cooling chamber to a CO₂ removalfilter. The method may comprise removing H₂ from gas directed from theCO₂ removal filter to an H₂ removal filter. The method may compriserecovering tail gas from the H₂ removal filter mixed gas outlet. Themethod may comprise recycling the tail gas through a tail gas recycleloop. Recycling the tail gas may comprise fluidly coupling at least onecooling chamber gas inlet port with the H₂ removal filter mixed gasoutlet through the tail gas recycle loop. Recycling the tail gas maycomprise fluidly coupling at least one cooling chamber gas inlet portwith the H₂ removal filter mixed gas outlet and a thermal oxidizerthrough the tail gas recycle loop. The method may comprise recyclingheat. Recycling heat may further comprise recycling heat generated fromthe tail gas by the thermal oxidizer. The method may comprise applyingthe heat generated from the tail gas by the thermal oxidizer to theprocessing chamber.

Various direct biochar cooling implementations may achieve one or moretechnical effect. For example, some direct biochar coolingimplementations may reduce installation, component, or maintenance cost.This facilitation may be a result of a direct biochar coolingimplementation designed to directly cool biochar using cool gascomprising steam or hydrocarbons, without a need for additionalcomponents to cool the biochar, such as, for example, a heat exchanger,or a cooling tower. Some direct biochar cooling implementations mayreduce operation cost. Such reduced operation cost may be a result of adirect biochar cooling implementation designed to directly cool biocharusing cool gas comprising steam or hydrocarbons, without requiringadditional energy inputs to cool the biochar using additional coolingcomponents. In some direct biochar cooling designs, valuable byproductsmay be produced. For example, biochar produced by steam direct coolingmay be valued at a higher price point than standard biochar produced byindirect cooling, and the biochar produced by steam direct cooling maybe a competitive alternative to activated carbon. Such higher-valuedbiochar produced by steam direct cooling may be a result of greaterbiochar surface area relative to standard biochar produced by indirectcooling.

Some direct biochar cooling implementations may produce biochar valuedas a high-grade carbon manufacturing input. For example, biocharproduced by some hydrocarbon direct cooling implementations may bevalued at a higher price point than standard biochar. This facilitationmay be a result of high grade carbon growth from the decomposition ofCH₄ in the gas, produced by hydrocarbon direct cooling of the biochar.Some direct biochar cooling implementations may produce a value-addchemical byproduct. Such a value-add chemical byproduct may be a resultof recycling and selling cooled hydrocarbon captured from an exemplaryhydrocarbon direct cooling implementation. Various direct biocharcooling implementations may enhance biochar quality. Such enhancedbiochar quality may be a result of directly cooling hot biocharresulting from gasification. Some direct biochar cooling implementationsmay capture hydrogen resulting from gasification. Such captured hydrogenproduction may enhance the efficiency of transition from a carbon-basedeconomy, and improve the usefulness of gasification technology.

In the case of hydrocarbon direct biochar cooling, a portion of thehydrocarbon gas may decompose with carbon attaching to biochar andhydrogen flowing through in the hot hydrocarbon mixed gas. The hothydrocarbon mixed gas may be cooled, and hydrogen may be stripped out orcaptured with a filter. In an illustrative example, ten percent or morehydrogen may be required to commercially apply such an exemplaryfiltration approach and recycle the cooled hydrocarbon mixed gas back tothe direct cooling step, with make-up from the pipeline, wellhead,digester, or the like, to repeat the process. In an illustrativeexample, this recovered hydrogen may be sold as a value-add chemicalbyproduct of an exemplary hydrocarbon direct biochar cooling system.

In an illustrative example, a direct biochar cooling implementation inaccordance with the present disclosure may directly cool hot biocharresulting from gasification, and in the process, enhance the biocharquality, or enhance the biochar quality and generate hydrogen.

In some implementations, an exemplary biochar and bio fly ash coolingapparatus may be a counter flow, direct contact exchange systemoperating on principles similar to a standpipe. An exemplary apparatusmay include a metal cylinder of an appropriate composition for theconditions, but may require a refractory or other lining for hightemperature operation. In various examples illustrative of the designand usage of various biochar cooling implementations in accordance withthe present disclosure, solids may enter the top of an exchanger andflow via gravity through the cooler, exiting at the bottom. In such anexample, the gas stream may enter the cooler near the bottom of thecooler, and flow upward through the solids. The gas may also serve tofluidize the solids, enhancing the solids' flow through the cooler. Invarious exemplary implementations, the method of introducing the gas mayvary depending on, for example, flow and cooler size, however the methodof introducing the gas may either utilize a gas distributor in largersystems, or fluidization nozzles at the wall for smaller coolers. Thegas may exit near the top of the cooler. Depending on application, aseparation device, such as a small cyclone or filter, may be needed todisengage the gas and solids at the gas exit.

In various examples illustrative of prior art biochar coolingimplementation design and usage, there do not appear to be any biocharcooling approach to hot carbonaceous residue that utilizes an exemplarysteam direct biochar cooling or hydrocarbon gas direct biochar coolingdesign in accordance with the present disclosure.

Throughout this disclosure, the term “fluid” is used interchangeablywith the term “gas.” For example, an element that is “fluidly coupled”or “fluidly connected” or in “fluid communication” is capable to orwould be capable to be in a coupled, connected, or communication modewith respect to gas, fluid, gas and fluid, gas or fluid, or anycombination or mixture of gas or fluid. Throughout this disclosure, anelement that is “fluidly coupled” or “fluidly connected” or in “fluidcommunication,” as the terms are used herein, is also capable to orwould be capable to be in a coupled, connected, or communication modewith respect to fluid, solids, fluid and solids, fluid or solids, or anycombination or mixture of fluid or solids.

The details of various aspects are set forth in the accompanyingdrawings and the description below. Other features and advantages willbe apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a schematic of exemplary catalytic methane decomposition.

FIG. 2 depicts a schematic of exemplary nanocarbon and hydrogen gascreation.

FIG. 3 depicts a schematic of exemplary direct cooling of hot biocharwith cool dry steam as the hot biochar exits a gasifier or cyclone,enhancing the surface area of the biochar.

FIG. 4 depicts a schematic of exemplary direct cooling of hot biocharwith cool hydrocarbon gas as the hot biochar exits a gasifier orcyclone, enhancing the high-quality carbon content of the biochar withnano tube type carbon formation on the biochar [chemical vapordeposition], and producing a gas stream that may be filtered to recoverhydrogen.

FIG. 5 depicts a schematic of exemplary direct cooling of hot biocharwith cool hydrocarbon gas as the hot biochar exits a gasifier orcyclone, with exemplary tail gas recycling.

FIG. 6 depicts an exemplary downdraft gasifier implementation inaccordance with the present disclosure.

FIG. 7 depicts an exemplary fluidized bed gasifier implementation inaccordance with the present disclosure.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

To aid understanding, this document is organized as follows. First,catalytic methane decomposition and creation of nanocarbon tubes[chemical vapor deposition] and hydrogen gas are briefly introduced withreference to FIGS. 1-2. Then, with reference to FIGS. 3-5, thediscussion turns to exemplary implementations that illustrate directbiochar cooling designs. Specifically, direct biochar coolingimplementations designed to cool biochar based on steam and hydrocarbongas applied directly to biochar are disclosed. Finally, with referenceto FIGS. 6-7, illustrative downdraft and fluidized bed gasifierimplementations are presented, to explain applications of direct biocharcooling technology.

It is to be understood that the specific devices and processesillustrated in the attached drawings and described in the followingspecification are exemplary implementations of the inventive conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the implementations disclosedherein are not to be considered as limiting, unless the claims expresslystate otherwise.

FIG. 1 depicts a schematic of exemplary catalytic methane decomposition.In FIG. 1, the exemplary catalytic methane decomposition processcomprises low-temperature cracking of methane, producing CON-freehydrogen and solid carbon. Catalytic methane decomposition has theunique potential to make the swift transition for a fully decarbonizedeconomy and beyond: the methane decomposition of biomethane removes CO₂from the atmosphere at competitive cost.

FIG. 2 depicts a schematic of exemplary nanocarbon and hydrogen gascreation. In FIG. 2, gas comprising methane is decomposed by methanedecomposition. The gas comprising methane may be decomposed by methanedecomposition as a result of being run over a catalyst containing carbonin a heated reactor, to produce hydrogen and carbonnanotubes/nano-onions/graphite. Examples of catalysts commonly used formethane decomposition may include at least nickel, cobalt, iron ore, orhematite iron ore. The gas comprising methane may be decomposed bymethane decomposition as a result of being run over a thermochemicallyconverted carbonaceous material in a heated vessel, which decomposes themethane into hydrogen and carbon. The hydrogen may remain in gaseousform. The hydrogen may be recovered. The carbon may aggregate in solidform with carbonaceous residue. The carbon may be recovered.Gasification is a thermochemical process in which the reactions betweenfuel and the gasification agent take place and syngas (also known asproducer gas, product gas, synthetic gas, or synthesis gas) is produced.The syngas may be mainly composed of CO, H₂, N₂, CO₂, and somehydrocarbons (CH₄, C₂H₄, C₂H₆, and the like).

FIG. 3 depicts a schematic of exemplary direct cooling of hot biocharwith cool dry steam as the hot biochar exits a gasifier or cyclone,enhancing the surface area of the biochar. In the steam direct biocharcooling implementation 300 depicted by FIG. 3, hot carbonaceous solidresidue (“hot biochar”) 335 is expelled from a gasifier. The gasifiermay be a downdraft gasifier. The gasifier may be a fluidized bedgasifier. The downdraft gasifier may be, for example, the exemplarydowndraft gasifier 600 described at least with reference to FIG. 6. Thefluidized bed gasifier may be, for example, the exemplary fluidized bedgasifier 700 described at least with reference to FIG. 7. The gasifiermay be operably connected with the steam direct biochar coolingimplementation 300 by the flange 330. In an illustrative downdraftgasifier example, hot carbonaceous residue from the downdraft gasifier(“hot biochar”) 335 may be expelled from the downdraft gasifier throughthe flange 330. In an illustrative fluidized bed gasifier example, hotcarbonaceous residue from the gasifier (“hot biochar”) 335 may beexpelled from the gasifier cyclone through the flange 330. In theillustrated example, the hot biochar 335 is expelled from the gasifierthrough the flange 330 and the feed mechanism 320 to the solid residuedischarge valve 315 directing the biochar flow 325 into the coolingchamber 305. In the example depicted by FIG. 3, the cooling chamber 305is configured with the direct steam 360 input interface valve 340 fed byrecycled steam from the steam recycling loop 350. In the illustratedexample, steam from the alternative steam makeup 352 port is injectedinto the steam recycling loop 350.

The steam 360 injected into the cooling chamber 305 cools the hotcarbonaceous solid residue (“biochar”) 335 in the cooling chamber 305.In the depicted example, the cooled biochar 335 is then directed fromthe bottom of the cooling chamber 305 into the drying chamber 310through the discharge valve 315. During an exemplary cooling step,moisture from the steam 360 may be physically caught in the coolingbiochar 335 depending on the pore space and reactivity of the biochar335. In the illustrated example, the cooling steam 360 stream isdirected from the cooling chamber 305 through the particulate steamfilter 345 to remove particulates from the steam 360. The particulatesteam filter 345 may be a hot gas ceramic or sintered metal particulatefilter. In the depicted example, the steam 360 filtered by theparticulate steam filter 345 is cooled in the steam recycling loop 350using steam to liquid heat exchange between the steam recycling loop 350and the environment. The heat exchange may be enhanced by the heat sink355 configured in the steam recycling loop 350. The heat exchange may beenhanced by the steam injected from the steam makeup port 352 into thesteam recycling loop 350. For example, the steam makeup port 352 steammay be a different temperature than the steam 360 in the steam recyclingloop 350, to enhance cooling in the steam recycling loop 350. The steammakeup port 352 steam may be provided from the facility. In the depictedexample, the cooled steam 360 is re-routed through the steam recyclingloop 350 to the cooling chamber 305. Heat from the steam to liquid heatexchange in the steam recycling loop 350 may be captured from the heatsink 355 and used to produce thermal energy for steam, power, or co-heatand power applications within the facility.

In the example depicted by FIG. 3, the drying chamber 310 is configuredwith the direct inert gas 370 input interface fed by the recycled supplyof dry inert gas 370 from the gas loop 380. During an exemplary dryingstep, moisture caught in the biochar may be swept away, producing thedried cooled biochar 375. In the illustrated example, the inert gas 370moistened in the drying chamber 310 is directed through the particulategas filter 365 to remove particulates from the inert gas 370. Theparticulate gas filter 365 may be a hot gas ceramic or sintered metalfilter. In the depicted example, the moistened inert gas 370 from theparticulate gas filter 365 is cooled in the gas loop 380. The moistenedinert gas 370 from the particulate gas filter 365 may be cooled in thegas loop 380 using a chiller. The moistened inert gas 370 from theparticulate gas filter 365 may be cooled in the gas loop 380 using heatexchange between the gas loop 380 and the environment. The moistenedinert gas 370 from the particulate gas filter 365 may be cooled in thegas loop 380 using heat exchange enhanced by the heat sink 355configured in the gas loop 380. Heat from the heat exchange in the gasloop 380 may be captured from the heat sink 355 and used to producethermal energy for steam, power, or co-heat and power applicationswithin the facility. Makeup inert gas may be injected into the gas loop380 from makeup inert gas port 372 to enhance cooling the gas 370 orenhance moisture removal from the gas 370. The makeup inert gas injectedfrom makeup inert gas port 372 may have a different moisture level thanthe gas in the gas loop 380. The makeup inert gas injected from makeupinert gas port 372 may be a different temperature than the gas in thegas loop 380, to enhance cooling in the gas loop 380. In the depictedexample, the filtered and cooled inert gas 370 is recycled through thegas loop 380 back to the drying chamber 310. Following the dryingchamber 310, the resultant biochar 375 may be directed to existingbiochar sizing, handling and storage for 3rd party sale or internal use.

In the example depicted by FIG. 3, the inlet flange 330 that connectsthe cooling chamber 305 to the gasifier and/or the cyclone via thedischarge valve 315 represents the point at which the exemplary steamdirect biochar cooling implementation 300 begins. Various steam directbiochar cooling implementation 300 designs may include: i) one or moredischarge valve 315 from the gasifier and/or the cyclone(s), ii) one ormore feed mechanism 320 from the discharge valve 315 to the coolingchamber 305, iii) the cooling chamber 305, iv) one or more hot gasceramic or sintered metal filter 345 for the removal of particulatesfrom the steam post cooling, v) the steam recycling loop 350 system withheat exchange and steam makeup port 352, vi) the drying chamber 310,vii) one or more hot gas ceramic or sintered metal filter 365 for theremoval of particulates from the inert gas post drying, viii)) the inertgas loop 380 recycling system with heat exchange and gas make-up 372,and ix) piping, conduit, wiring, and control systems to effectuate allof the described functions.

In the depicted example, the drying chamber 310 is connected by theoutlet discharge valve 315 with the outlet flange 330 through which thecooled carbonaceous solid residue (“cooled biochar”) 375 is expelled. Inthe illustrated example, the particulate steam filter 345 or theparticulate gas filter 365 may be configured with a particulate removalvalve connected with the filters by a flange 330 (not shown). In thedepicted example, the steam recycling loop 350 or the gas loop 380 maybe configured with a heat exchanger comprising one or more heat sink355. The heat exchanger configured in the steam recycling loop 350 maybe connected with the particulate steam filter 345 by a flange 330 (notshown). The heat exchanger configured in the gas loop 380 may beconnected with the particulate gas filter 365 by a flange 330 (notshown). In an example illustrative of various steam direct biocharcooling implementations in accordance with the present disclosure, theflange 330 connections proximal to the drying chamber 310, flange 330connections to the filters, the steam makeup port 352, and the inert gasmakeup port 372 represent points at which the exemplary steam directbiochar cooling implementation 300 may end.

In an illustrative example, the depicted steam direct biochar coolingimplementation 300 may permit a more cost-effective means of coolinggasification hot carbonaceous solid residues.

For example, a steam direct biochar cooling implementation in accordancewith the present disclosure may take advantage of the physical andcompositional properties of the gasification hot carbonaceous solidresidue and the compositional properties of the steam and inert gas, toaugment the resultant hot carbonaceous solid residue that renders theresultant biochar more suitable for certain product applications,increasing the biochar's overall commercial value.

Various steam direct biochar cooling implementations in accordance withthe present disclosure may utilize recycling loops to minimize water andinert gas resource inputs, and improve the efficiency of energy usage bybiochar cooling.

Some steam direct biochar cooling implementations in accordance with thepresent disclosure may be configured with one or more heat exchangerdesigned to maximize process heat recovery, and minimize energy resourceinputs.

A steam direct biochar cooling implementation in accordance with thepresent disclosure may include a dutchman style feed system setup on thebottom of the discharge valve(s) to provide flow variances between thegasifier and the cooling chamber. Some steam direct biochar coolingimplementations in accordance with the present disclosure may includehot gas particulate removal systems, such as, for example, a bag housesystem, or quench scrubber system, applied as an alternative to a hotgas ceramic or sintered metal filter.

In an illustrative example, a steam direct biochar coolingimplementation in accordance with the present disclosure may beconfigured to receive independently produced and heated biochar, usingthe biochar as a means to convert that heated biochar into a biochardifferent in composition and physical format from the original biochar,for specific product applications.

In an illustrative example, pre-cooling of the cooling gas media priorto cooling chamber injection may be employed to ensure the stream issufficiently cooled to reduce the temperature of the gasification hotcarbonaceous solid residue (hot biochar). Some implementations mayadjust the moisture content of the stream to prevent the stream frombecoming too wet. A stream that is too wet may cause the creation of aresidue slurry that cannot be effectively dried by inert gas drying, if,for example, the inert gas is not dry enough to sweep the caughtmoisture from the gasification cooled carbonaceous solid residue (cooledbiochar); or if carry over of too many particulates in the steam postcooling or inert gas post drying impede the filtration systems' abilityto effectively remove particulates prior to the recycling loops.

In an illustrative example, component parts may comprise sufficientquality steel material to account for the pressures (1-500 psig/1-35Bar), temperatures (212°-1500° F. or 100°-800° C.) and corrosiveness ofthe substances involved. In an illustrative example, one could expect toutilize at least some component parts comprising stainless steel in anexemplary implementation in accordance with the present disclosure, toaccount for the operational pressures and temperatures expected.

An exemplary steam direct biochar cooling implementation may takeadvantage of temperature, pressure, and composition of the gasificationhot carbonaceous material (hot biochar), the cooling steam and thedrying inert gas, to create cooled biochar with high value applicationopportunities.

FIG. 4 depicts a schematic of exemplary direct cooling of hot biocharwith cool hydrocarbon gas as the hot biochar exits a gasifier orcyclone, enhancing the high-quality carbon content of the biochar withnano tube type carbon formation on the biochar, and producing a gasstream that may be filtered to recover hydrogen. FIG. 5 depicts aschematic of exemplary direct cooling of hot biochar with coolhydrocarbon gas as the hot biochar exits a gasifier or cyclone, withexemplary tail gas recycling.

In FIG. 4, the depicted hydrocarbon gas direct biochar coolingimplementation 400 is configured to cool hot biochar 335 based on directapplication of heat, pure hydrocarbon gas streams, or mixed gas streams(such as, for example, natural gas, biogas, well head gas and coal bedmethane, or the like) to produce the cooled biochar 375 that isdifferent in composition and physical format from biochar produced byindirect processing and cooling. In an illustrative example, thisresultant cooled biochar 375 produced based on direct application ofheat, pure hydrocarbon gas streams or mixed gas streams to the hotbiochar 335 may be more suitable for certain product applications. Forexample, in various hydrocarbon gas direct biochar coolingimplementations in accordance with the present disclosure, theprocessing and cooling media may be purified and refined as the hotcarbonaceous solid gasification residue is processed and cooled. In anexample illustrative of various hydrocarbon gas direct biochar coolingimplementation designs, the CO₂ content of the cooling gas stream may beextracted utilizing filtration technology adapted from the sour gas andbiogas upgrading industry applications. The hydrogen content of thecooled gas stream may be extracted utilizing filtration technology usedin hydrogen production technologies. In FIG. 5, the depicted hydrocarbongas direct biochar cooling implementation 500 further comprisesexemplary tail gas recycling features with the direct biochar coolingfeatures described with reference to the hydrocarbon gas direct biocharcooling implementation 400 described with reference to FIG. 4.

In the hydrocarbon gas direct biochar cooling implementation 400depicted by FIG. 4 and the hydrocarbon gas direct biochar cooling withtail gas recycling implementation 500 depicted by FIG. 5, hotcarbonaceous solid residue (“hot biochar”) 335 is expelled from agasifier. The gasifier may be a downdraft gasifier. The gasifier may bea fluidized bed gasifier. The downdraft gasifier may be, for example,the exemplary downdraft gasifier 600 described at least with referenceto FIG. 6. The fluidized bed gasifier may be, for example, the exemplaryfluidized bed gasifier 700 described at least with reference to FIG. 7.The gasifier may be operably connected by the flange 330 with thehydrocarbon gas direct biochar cooling implementation 400 depicted byFIG. 4, or the hydrocarbon gas direct biochar cooling with tail gasrecycling implementation 500 depicted by FIG. 5.

In the hydrocarbon gas direct biochar cooling implementation exampledepicted by FIG. 4, hot carbonaceous solid gasification residue(biochar) 335 is directed into the processing chamber 405 as the residue(biochar) 335 is expelled from the downdraft gasifier at the solidresidue discharge valve(s) 315, or from the downdraft gasifier or thefluidized bed gasifier at the cyclone solid residue discharge valve(s)315. In the examples depicted by FIGS. 4 and 5, the processing chamber405 includes the heating element 415. The heating element 415 may be anindirect heating element. The indirect heating element 415 may be agas/liquid to gas heat exchange that can boost the solids temperaturefrom 400°-800° C. or higher, if necessary, to achieve gasification hotcarbonaceous solid residue (biochar) 335 processing temperatures.

In an exemplary cooling step, the hot carbonaceous solid residues(biochar) 335 are next directed to the cooling chamber 410. In theexample depicted by FIG. 4, the cooling chamber 410 is configured withthe direct gas 425 input interface. The direct gas 425 input interfacemay be fed, for example, by hydrocarbon gas streams (natural gas,biogas, well head gas and coal bed methane, and the like) from afacility processing unit or a pipeline interconnection. In anillustrative example, the hydrocarbon direct gas 425 reacts with the hotcarbonaceous solid residue (biochar) 335 in the cooling chamber 410,cooling the residue (cooling biochar) 335 creating cooled biochar 375(also known as bio fly ash when recovered from a cyclone) that is thendirected from the bottom of the cooling chamber 410. In the depictedexample, the processing chamber 405 is configured to receive recoveredprocess heat 420 to enhance the hydrocarbon direct gas 425 reaction withthe hot carbonaceous solid residue (biochar) 335 in the cooling chamber410. The cooled biochar 375 may be directed to a biochar recoverysizing, storage, or packaging system for distribution. In someimplementations, the heating element 415 may be deactivated in responseto determining the recovered process heat 420 reaches at least apredetermined minimum temperature. In an illustrative example, theheating element 415 may be used to heat biochar 335 in the processingchamber 405. The biochar 335 may be heated in the processing chamber 405using process heat 420. An exemplary biochar cooling implementation mayinitially heat biochar 335 in the processing chamber 405 using theheating element 415, deactivate the heating element 415 when the processheat 420 reaches at least a predetermined minimum temperature, andcontinue heating biochar 335 in the processing chamber using only, orsubstantially only, process heat 420. In an illustrative example, theprocess heat 420 may be generated by a thermal oxidizer supplied withtail gas filtered from gas released from the cooling chamber 410.

In various hydrocarbon gas direct biochar cooling implementations inaccordance with the present disclosure, during an exemplary coolingstep, compounds and elements within the cooling gaseous media such ascarbon, hydrogen sulfide, siloxanes, and the like may be physicallycaptured in the cooling carbonaceous solid residue (biochar) 335 orchemically bound in the cooled carbonaceous solid residue (biochar) 375depending on the pore space or reactivity of the carbonaceous solidresidue (biochar) 335, augmenting the compositional aspects of theresultant cooled biochar 375. During the cooling step, physicalexpansion and reduction activities may alter the physical nature of theresulting carbonaceous solid residue (cooled biochar) 375. Suchaugmentations may enhance the applicability of the biochar 375 forcertain product applications that may take advantage of these physicalor compositional aspects of the resultant biochar 375, such as greatersurface area, greater cat ion exchange capability, or nano structurecarbon formations.

During the cooling step, the temperature of the carbonaceous solidresidue (cooling biochar) 335 and/or the catalytic properties of thecompositional make-up of the cooling biochar 335 may facilitate chemicalreactions with the hydrocarbon gas 425, such as, for example, methanedecomposition, forming a resulting mixed gaseous stream suitable forrecovery of valuable gas streams, such as, for example, CO₂, orhydrogen. In the depicted examples, the resulting mixed gaseous streamexiting the cooling chamber 410 is then directed via the valve 430through the hot gas ceramic or sintered metal particulate gas filter 365to remove particulates from the post cooling gaseous media. In theillustrated examples, the valve 430 is a three-way valve configured topermit coupling the gas chromatograph 435 to the valve 430 to measurethe chemical composition of the mixed gaseous stream exiting the coolingchamber 410. In the depicted examples, after particulates are filteredfrom the post cooling gaseous media, the filtered mixed gaseous streamis directed to various filtration systems for the capture, recovery, andbeneficial use of these valuable gas streams. In the depicted examples,the filtered mixed gaseous stream is directed from the particulate gasfilter 365 output to the CO₂ removal filter 440, resulting in the carbondioxide 445 stream at the CO₂ removal filter 440 carbon dioxide output.The carbon dioxide 445 stream filtered from the mixed gaseous stream maybe recovered, distributed, or sold. In the depicted examples, the mixedgaseous stream filtered by the CO₂ removal filter 440 is directed fromthe CO₂ removal filter 440 mixed gaseous stream output to the H₂ removalfilter 450, resulting in the tail gas stream 455 and the hydrogen stream460. In various exemplary hydrocarbon gas direct biochar coolingimplementations in accordance with the present disclosure, residual tailgas from the tail gas stream 455 may be recycled within the system, toimprove biochar cooling efficiency and reduce harmful impact to theglobal human environment. In the example depicted by FIG. 5, residualtail gas from the tail gas stream 455 may be cooled via heat exchangeand the tail gas may recycled via the tail gas recycle loop 520 back tothe cooling chamber 410. In the example illustrated by FIG. 5, residualtail gas from the tail gas stream 455 may also be cooled via heatexchange and directed to the thermal oxidizer 505. In the exampledepicted by FIG. 5, the tail gas stream 455 directed to the thermaloxidizer 505 permits the thermal oxidizer 505 to produce thermal energy.The thermal energy 510 produced by the thermal oxidizer 505 may then berecovered from the exhaust gas 525 via the heat exchanger 530. Invarious implementations, the thermal energy 510 recovered from thethermal oxidizer 505 may be employed to heat the processing chamber 405.The processing chamber 405 may be heated by alternate heat source 515.In some implementations, the thermal energy recovered from the thermaloxidizer 505 may be employed to produce thermal energy for heat, power,or co-heat and power applications.

In the examples depicted by FIGS. 4 and 5, the inlet flange 330 thatconnects the processing chamber 405 to the gasifier and/or the cyclonevia the discharge valve 315 represents the point at which the exemplaryhydrocarbon gas direct biochar cooling implementations may begin.Various hydrocarbon gas direct biochar cooling implementation 400 or 500designs may include i) one or more discharge valve 315 from the gasifierand/or the cyclone(s), ii) one or more feed mechanism 320 from thedischarge valve 315 to the processing chamber 405 and the coolingchamber 410, iii) the processing chamber 405 and the cooling chamber410, iv) a biochar recovery sizing, storage, and packaging system (notshown), v) the incorporation/utilization of the hot gas ceramic orsintered metal filter 365 for the removal of particulates from the postcooling gaseous media, vi) the incorporation/utilization of the CO₂removal filter 440 and hydrogen removal filter 450 for the recovery ofthese gas streams from the post cooling gaseous media, vii), the heatexchange cooling and recycle loop 520, viii) theincorporation/utilization of the thermal oxidizer 505 and the exhaustgas 525 heat exchanger 530 to recover thermal energy 420 from theresidual tail gas, to provide process heat 415 to the processing chamber405 via gas to gas heat exchange, or for the production of heat, power,or co-heat and power and ix) all piping, conduit, and wiring controlsystems to effectuate all of the described functions.

Various exemplary hydrocarbon gas direct biochar cooling implementationsin accordance with the present disclosure may permit more cost-effectiveprocessing and cooling of gasification hot carbonaceous solid residue.Such improved gasification hot carbonaceous solid residue processing andcooling cost effectiveness may be a result of a biochar coolingimplementation designed to take advantage of the physical andcompositional properties of the gasification hot carbonaceous solidresidue and the compositional properties of the hydrocarbon gas to costeffectively augment the resultant hot carbonaceous solid residue withelements and compounds that render the resultant biochar more suitablefor certain product applications, increasing the biochar's overallcommercial value.

An exemplary hydrocarbon gas direct biochar cooling implementation inaccordance with the present disclosure may take advantage of thephysical and compositional properties of the gasification hotcarbonaceous solid residue and the hydrocarbon gas to cost effectivelypurify and refine the hydrocarbon gas into purified and refined gasstreams that may comprise, for example, CO₂ or hydrogen, that, throughthe use of filtration technology, can be captured and recovered for highvalue beneficial use applications or beneficial sequestration in thecontext of CO₂.

Some exemplary hydrocarbon gas direct biochar cooling implementations inaccordance with the present disclosure may include a dutchman style feedsystem setup on the bottom of the discharge valve(s) to provide flowvariances between the gasifier and the processing chamber.

In an exemplary hydrocarbon gas direct biochar cooling implementation inaccordance with the present disclosure, the processing chamber andcooling chamber may be configured as one piece of equipment, with a topto bottom gasification hot carbonaceous solid residue flowcharacteristic.

Alternative hot gas particulate removal systems, such as, for example, abag house system, or a quench scrubber system, could be applied to thepost cooling gaseous media used in some exemplary hydrocarbon gas directbiochar cooling implementations, as an alternative to a hot gas ceramicor sintered metal filter.

In an illustrative example, an alternative gas recovery systems could beapplied to the purified and refined cooling gas stream in somehydrocarbon gas direct biochar cooling designs, such as pressure swingadsorption, temperature swing adsorption, amine scrubbing, biologicalscrubbing, or the like, to capture, recover, and beneficially use thevaluable gas streams inherent therein.

In an illustrative example, an exemplary hydrocarbon gas direct biocharcooling implementation in accordance with the present disclosure may beconfigured to independently heat cooled biochar and use the heatedbiochar as a means to convert that heated biochar using heat, purehydrocarbon gas streams, or mixed gas streams (natural gas, biogas, wellhead gas and coal bed methane, or the like) into a biochar different incomposition and physical format from the original biochar, for specificproduct applications. Various exemplary hydrocarbon gas direct biocharcooling designs may also be used to cost effectively purify and refinehydrocarbon gas streams (natural gas, biogas, well head gas and coal bedmethane, or the like) into valuable gas streams for the capture andrecovery of CO₂ or hydrogen for useful applications or beneficialsequestration in the context of CO₂.

Various exemplary hydrocarbon gas direct biochar cooling designs mayinclude pre-cooling of the hydrocarbon prior to cooling chamberinjection, to ensure the hydrocarbon is sufficiently cooled to reducethe temperature of the gasification hot solid residue. In anillustrative example, the temperature of gasification hot solid residue(biochar) will have an impact on the biochar's capabilities associatedwith purifying and refining the cooling media.

In an illustrative example, component parts may comprise sufficientquality steel material to account for the pressures (1-500 psig/1-35Bar), temperatures (212°-1500° F. or 100°-800° C.) and corrosiveness ofthe substances involved. In an illustrative example, one could expect toutilize at least some component parts comprising stainless steel in anexemplary implementation in accordance with the present disclosure, toaccount for the operational pressures and temperatures expected.

An exemplary hydrocarbon gas direct biochar cooling design may takeadvantage of temperature, pressure, and composition of the gasificationhot carbonaceous material (hot biochar) and the hydrocarbon gas tocreate cooled biochar with high value application opportunities, andenable the capture and recovery of purified and refined high value gasstreams for beneficial use, products, production, or sequestration. Thisfacilitation may be a result of a direct biochar cooling implementationdesigned to avoid sweeping the heat away in the form of a hot transfermedia which then must be cooled via a cooling tower arrangement, ordischarged as a waste stream in once through cooling applications, whichmay be disadvantages related to indirect cooling designs that may coolbiochar based on heat exchange.

In an illustrative example, an exemplary hydrocarbon gas direct biocharcooling implementation may be employed wherever a gasification systemexists. Other applicable industries for the disclosed steam direct andhydrocarbon gas direct biochar cooling technologies include, forexample, producers of biochar interested in augmenting their biocharproduct for higher value applications; producers of purified gas streamsfor beneficial use applications or sequestration; wastewater treatmentplants and biosolid aggregators; wood and agricultural processors andbiomass/biomass waste aggregators; consumers that are looking forspecialty carbon materials for advance bioproduct manufacturing; andland remediators, water pollution control system providers, and odorcontrol system providers.

FIG. 6 depicts an exemplary downdraft gasifier implementation inaccordance with the present disclosure. Disclosed is a gasifiercomprising a plurality of conjoined and vertically positioned tubes. Thetubes have an interior wall and exterior wall and a proximal and distalend wherein the proximal end provides an inlet and the distal endprovides an outlet. The gasifier has three separate reaction zones: (1)a Pyrolysis Zone; (2) an Oxidation Zone beneath the Pyrolysis Zone; and(3) a Reduction Zone beneath the Oxidation Zone. A rotating andvertically adjustable grate is located below, but not attached to, theReduction Zone. Unlike other gasifiers, this is a partially open coregasifier without an airtight seal on the distal end of the gasifier. TheProducer Gas exits through the grate and is collected by collectionvents on the sides of the collection chutes.

In FIG. 6, arrows depict an exemplary gasification process in theexemplary downdraft gasifier 600. Three types of Oxidant Streams enterthe gasifier through three separate, corresponding inlet points: PurgeOxidant Streams, Bed Oxidant Streams and Plano Oxidant Streams. ThePurge Oxidant Stream is the Oxidant Stream that is introduced to thefeedstock and enters the gasifier with the feedstock through a PressureLock. The Purge Oxidant Stream also prevents tarry gases fromback-flowing into the Pressure Lock. The Bed Oxidant Stream enters thegasifier through inlets 611 located at the top of the gasifier. ThePlano Oxidant Streams enter the gasifier through the Plano Air Inlets631, 632 located in rings around the perimeter of the Oxidation Zone630. In the depicted example, an exemplary Control System monitors andadjusts each of these Oxidant Streams to control the total amount ofOxygen in each zone of the gasifier and the rate of Producer Gas beinggenerated. The Control System can adjust the volume and velocity of thisOxidant Stream to adjust for feedstock having differing moisturecontents, bulk densities, or even because of changes in the BTU value ofa feedstock. The Control System allows for the changes to be made whilethe gasifier is in operation, so that it does not need to be shut downor be reconfigured. In the depicted implementation, the gasifierincludes the Pyrolysis Zone 620, the Oxidation Zone 630, and theReduction Zone 640 with a grate located underneath the gasifier. Belowthe gasifier are gas collection vents, and Biochar collection chutes.

The Oxidation Zone 630 is the zone in the gasifier leading up to andaway from the Oxidation Band 650 or the general step of the methodincluding formation of the Oxidation Band 650. The Oxidation Zone 630 iswhere the Oxidation Band 650 forms and represents the hottest step inthe gasification process and is where the cellulosic fraction of thefeedstock converts from a solid to a gas. The more Oxygen fed to thegasifier the faster the feedstock is gasified in the Oxidation Zone 630.The faster the reaction, the more Biochar is produced and accumulates inthe Reduction Zone 640.

During operation, the flow of an Oxidant Stream through Pyrolysis Zone620 induces a feedstock gradient to form (1) vertically, beginningtoward the top of the outside wall of the Pyrolysis Zone 620 and endingdown at a lower ring of Plano Air Inlets 631, 632 in the Oxidation Zone630 and (2) horizontally, beginning in the center of the gasifier andending at the wall of the gasifier (the “Induced Feedstock Gradient”).This Induced Feedstock Gradient is an increasing and differentialdensity of feedstock becoming denser toward the perimeter of thegasifier wall and above the Oxidation Band 650 (the “Densest Portion”)formed by at least four factors acting in concert: (1) the Pressure Wavefrom the Oxidation Band 650 pressing feedstock against the interior wallof the gasifier; (2) the geometry of the Pyrolysis Zone 620 and theOxidation Zone 630 (i.e., angles of the walls); (3) the total volume ofthe Oxidant Stream flowing into the Pyrolysis Zone 620 and the OxidationZone 630; and (4) the relative volume of the Oxidant Stream flowing intoeach of the Pyrolysis Zone 620 and the Oxidation Zone 630. The DensestPortion of the Induced Feedstock Gradient is illustrated at 660. AsBiochar leaves the Oxidation Band 650, the diameter of the OxidationZone 630 narrows to approximately the same size as the inlet to theOxidation Zone 630. The Pressure Wave from the Oxidation Band 650 pushesthe Biochar against the narrowing wall of the Oxidation Zone. TheDensest Portion of this Entrained Biochar Gradient is illustrated at670. The Pressure Wave slows the movement of the Densest Portion of theBiochar in the Entrained Biochar Gradient 670 relative to Biochar.

Implementing a Control System for variable control of the Bypass 649 andthe Oxidant Stream in the gasifier also ensures the consistency andquality of the Producer Gas. The Bypass 649 functions to controlProducer Gas flow out of the Reduction Zone 640, the Bypass 649 actingsimilar to a valve. For example, a short Bypass increases resistance toProducer Gas flow through the grate and causes pressure to build in thegasifier.

There are several different redundant control methods used in thegasifier, and most function as a means by which more precise control canbe achieved throughout the process. In one embodiment, an effectivecontrol method is to monitor the thermal gradient, or profile, asindicated by the temperatures of each zone. These temperatures areobtained by way of embedded thermocouples inside of the lined wall ofthe gasifier. This temperature gradient, or profile, is a very goodindicator of where each zone is and where it is moving toward within thegasifier. In one embodiment, the Control System uses this information tochange the balance of Oxidant Stream at any given zone or to physicallychange the height of the bed of Biochar in the Reduction Zone 640 by wayof the grate rotation and bypass 649 to help maintain and/or sustaineach zone above it.

One embodiment improves the consistency of the Producer Gas by liningthe entire gasifier with silica carbide, silica oxide, aluminum oxide,refractory alloy, other ceramics or another material that is stable athigh temperatures. This lining helps to evenly distribute and conductheat out from the Oxidation Band 650 and allows the use of thermocoupleswhile protecting them from the reactions occurring inside the gasifier.

The Control System may use all of the different methods and combine saidmethods into an algorithmic controller. The latter does not only allowfor redundancy throughout the Control System but also ensures muchgreater reliability and efficiency. It furthermore ensures that theProducer Gas is of constant and high quality.

The application and method of gasification described above also providesan effective way of controlling the height of the Reduction Zone 640. Inone embodiment of this gasifier, the Oxidation Band 650 can move up intothe Pyrolysis Zone 620 or down into the Reduction Zone 640 and still becontrolled and/or maintained by way of where the Control System allowsthe Oxidant Stream to be placed and amount of Biochar being removed.Disruption to the height of the feedstock, or the differential pressureacross the gasifier can therefore be controlled by way of the graterotation without risking the Oxidation Band 650 collapse.

FIG. 7 depicts an exemplary fluidized bed gasifier implementation inaccordance with the present disclosure. FIG. 7 depicts the exemplarysmall and large-scale fluidized bed gasifier 700 designed to gasifybiosolids; wherein the large-scale gasifier includes a reactor vesselwith a pipe distributor and at least two fuel feed inlets for feedingbiosolids into the reactor vessel at a desired fuel feed rate of morethan 40 tons per day with an average fuel feed rate of about 100 tonsper day during steady-state operation of the gasifier. The fluidized bedin the base of the reactor vessel has a cross-sectional area that isproportional to at least the fuel feed rate such that the superficialvelocity of gas is in the range of 0.1 m/s (0.33 ft/s) to 3 m/s (9.84ft/s). In operation, biosolids are fed into a fluidized bed reactor andoxidant gases are applied to the fluidized bed reactor to produce asuperficial velocity of producer gas in the range of 0.1 m/s (0.33 ft/s)to 3 m/s (9.84 ft/s). The biosolids are heated inside the fluidized bedreactor in an oxygen-starved environment having a sub-stoichiometricoxygen level, whereby the biosolids are gasified. In an implementation,the internal diameter of the reactor is configured to ensure that thefluidized bed is able to be fluidized adequately for the desired fuelfeed rate and the flow rate of the fluidizing gas mixture at differentoperating temperature, yet prevent slugging fluidization as media isprojected up the freeboard section. Other factors may be used in thedesign and sizing of the gasifier, including internal diameter of thebed section, internal diameter of a freeboard section, height of thefreeboard section, bed depth and the bed section height to reach thetargeted fuel feed rate.

In the example depicted by FIG. 7, the exemplary gasifier 700 is ascaled-up implementation of a bubbling type fluidized bed gasifier 700.In an implementation, the bubbling fluidized bed gasifier 700 willinclude a reactor 799 operably connected to the feeder system (notshown) as an extended part of the standard gasifier system 700. Afluidized media bed 704A such as but not limited to quartz sand is inthe base of the reactor vessel called the reactor bed section 704. Thefluidized sand is a zone that has a temperature of 1150° F.-1600° F.Located above the reactor bed section 704 is a transition section 704Band above the transition section 704B is the freeboard section 705 ofthe reactor vessel 799. Fluidizing gas consisting of air, flue gas, pureoxygen or steam, or a combination thereof, is introduced into thefluidized bed reactor 799 to create a velocity range inside thefreeboard section 705 of the gasifier 700 that is in the range of 0.1m/s (0.33 ft/s) to 3 m/s (9.84 ft/s). The biosolids are heated insidethe fluidized bed reactor to a temperature range between 900° F. and1600° F. in an oxygen-starved environment having sub-stoichiometriclevels of oxygen, e.g., typically oxygen levels of less than 45% ofstoichiometric. In another embodiment, the fluidized sand is a zone thathas a temperature of 1150° F.-1600° F.

The reactor fluidized bed section 704 of a fluidized bubbling bedgasifier 700 is filled with a fluidizing media 704A that may be a sand(e.g., quartz or olivine), or any other suitable fluidizing media knownin the industry. Feedstock such, as but not limited to sludge, issupplied to the reactor bed section 704 through fuel feed inlets 701 at40° F.-250° F. In one embodiment the feedstock is supplied to thereactor bed section 704 through fuel feed inlets 701 at 215° F.; withthe gas inlet 703 in the bubbling bed receiving an oxidant-basedfluidization gas such as but not limited to e.g., gas, flue gas,recycled flue gas, air, enriched air and any combination thereof(hereafter referred to generically as “gas” or “air”). In one embodimentthe air is at about 600° F. The type and temperature of the air isdetermined by the gasification fluidization and temperature controlrequirements for a particular feedstock. The fluidization gas is fed tothe bubbling bed via a gas distributor. An oxygen-monitor 709 may beprovided in communication with the fluidization gas inlet 703 to monitoroxygen concentration in connection with controlling oxygen levels in thegasification process. An inclined or over-fire natural gas burner (notvisible) located on the side of the reactor vessel 799 receives anatural gas and air mixture via a port 702. In one embodiment, thenatural gas air mixture is 77° F. which may be used to start up thegasifier and heat the fluidized bed media 704A. When the minimumignition temperature for self-sustaining of the gasification reactionsis reached (about 900° F.), the natural gas is shut off. View ports 706and a media fill port 712 are also provided.

In one embodiment, a freeboard section 705 is provided between thefluidized bed section 704 and the producer gas outlet 710 of thegasifier reactor vessel 799. As the biosolids thermally decompose andtransform in the fluidized bed media section (or sand zone) intoproducer gas and then rise through the reactor vessel 799, thefluidizing medium 704A in the fluidized bed section 704 is disentrainedfrom the producer gas in the freeboard section 705 which is also knownas and called a particle disengaging zone. A cyclone separator 707 maybe provided to separate material exhausted from the fluidized bedreactor 799 resulting in clean producer gas for recovery with ashexiting the bottom of the cyclone separator 707 alternatively for use ordisposal.

An ash grate 711 may be fitted below the gasifier vessel for bottom ashremoval. The ash grate 711 may be used as a sifting device to remove anylarge inert, agglomerated or heavy particles so that the fluidizingmedia and unreacted char can be reintroduced into the gasifier forcontinued utilization. In one embodiment, a valve such as but notlimited to slide valve 713 which is operated by a mechanism to open theslide valve 714 is located beneath the ash grate 711 to collect the ash.In one embodiment, a second valve 713 and operating mechanism 714 (notshown) are also located below the cyclone separator 707 for the samepurpose. That is, as a sifting device to remove any large inert,agglomerated or heavy particles so that the fluidizing media andunreacted char can be reintroduced into the gasifier for continuedutilization. In one embodiment the ash grate 711 may be a generic solidsremoval device known to those of ordinary skill in the art. In anotherembodiment, the ash grate 711 may be replaced by or combined with theuse of an overflow nozzle.

The producer gas control 708 monitors oxygen and carbon monoxide levelsin the producer gas and controls the process accordingly. In oneembodiment a gasifier feed system (not shown) feeds the gasifier reactor799 through the fluidized fuel inlets 701. In one embodiment, thegasifier unit 700 is of the bubbling fluidized bed type with a customfluidizing gas delivery system and multiple instrument control. Thegasifier reactor 799 provides the ability to continuously operate,discharge ash and recycle flue gas for optimum operation. The gasifierreactor 799 can be designed to provide optimum control of feed rate,temperature, reaction rate and conversion of varying feedstock intoproducer gas.

A number of thermocouple probes (not shown) are placed in the gasifierreactor 799 to monitor the temperature profile throughout the gasifier.Some of the thermal probes are placed in the fluidized bed section 704of the gasifier rector 799, while others are placed in the freeboardsection 705 of the gasifier. The thermal probes placed in the fluidizedbed section 704 are used not only to monitor the bed temperature but arealso control points that are coupled to the gasifier air system via port702 in order to maintain a certain temperature profile in the bed offluidizing media. There are also a number of additional controlinstruments and sensors that may be placed in the gasifier system 700 tomonitor the pressure differential across the bed section 704 and theoperating pressure of the gasifier in the freeboard section 705. Theseadditional instruments are used to monitor the conditions within thegasifier as well to as control other ancillary equipment and processesto maintain the desired operating conditions within the gasifier.Examples of such ancillary equipment and processes include but are notlimited to the cyclone, thermal oxidizer and recirculating flue gassystem and air delivery systems. These control instruments and sensorsare well known in the industry and therefore not illustrated.

An optional ash grate 711 may be fitted below the gasifier vessel forbottom ash removal. The ash grate 711 may be used as a sifting device toremove any agglomerated particles so that the fluidizing media andunreacted char can be reintroduced into the gasifier for continuedutilization. In one embodiment, a slide valve 713 operated by amechanism to open the slide valve 714 is located beneath the ash grate711 to collect the ash. In one embodiment, a second slide valve 713 andoperating mechanism 714 are located below the cyclone separator 707.

As with the small format fluidized bed gasifier, some unreacted carbonis carried into the cyclone separator 707 with particle sizes rangingfrom 10 to 300 microns. When the solids are removed from the bottom ofthe cyclone, the ash and unreacted carbon can be separated and much ofthe unreacted carbon recycled back into the biogasifier, thus increasingthe overall fuel conversion to at least 95%. Ash accumulation in the bedof fluidizing media may be alleviated through adjusting the superficialvelocity of the gases rising inside the reactor. Alternatively, bedmedia and ash could be slowly drained out of the gasifier base andscreened over an ash grate 711 before being reintroduced back into thebiogasifier. This process can be used to remove small, agglomeratedparticles should they form in the bed of fluidizing media and can alsobe used to control the ash-to-media ratio within the fluidized bed.

A feedstock such as but not limited to biosolid material can be fed intothe gasifier by way of the fuel feed inlets 701 from more than onelocation on the reactor vessel 799 and wherein said fuel feed inlets 701may be variably sized such that the desired volumes of feedstock are fedinto the gasifier through multiple feed inlets 701 around the reactorvessel 799 to accommodate a continuous feed process to the gasifier. Forthe present invention and in one embodiment, the number of fuel feedinlets is between 2-4. The minimum number of feed inlets 701 is based,in part, on the extent of extent of back mixing and radial mixing of thechar particles in the bed and on the inside diameter of the reactor bedsection 704. For bubbling fluidized beds, one feed point could beprovided per 20 ft² of bed cross sectional area. For example, and in oneembodiment, if the reaction bed section has an internal diameter of 9ft, the reactor vessel 799 will have at least 3 feed inlets 701 (locatedequidistant radially to maintain in-bed mixing. Feed inlets 701 may beconsidered all on one level, or on more than one level or differentlevels and different sizes.

Although various features have been described with reference to theFigures, other features are possible. For example, catalytic methanedecomposition is a promising pathway for the energy transition to adecarbonized economy. Catalysts and reactor designs are being optimizedto increase reaction stability. In addition, carbon is a valuableby-product with the potential creation of new markets, and catalystregeneration may be employed and optimized for long-term stability. Incombination, such exemplary lines of research may reduce CO₂ emissionsbased on gradually replacing fossil fuels by a hydrogen-based economy.

A direct biochar cooling system implementation in accordance with thepresent disclosure may produce biochar having enhanced carbon contentwith increased surface area, and a hydrogen stream byproduct. In thecase of hydrocarbon direct biochar cooling, the resultant biochar mayhave high grade carbon growth from the decomposition of CH₄ in the gas,which has a higher price point than standard biochar as a high-gradecarbon manufacturing input.

An implementation in accordance with the present disclosure, of steamdirect biochar cooling or hydrocarbon gas direct biochar cooling maycost less to install and operate, and produce more valuable byproducts,than an indirect biochar cooling implementation. In the case of steamdirect biochar cooling, the resultant biochar may have a greater surfacearea, which has a higher price point than standard biochar, and may be acompetitive alternative to activated carbon.

In illustrative examples, low-cost biochar produced from biomassproducts (wood and wood residues, agricultural and agriculturalresidues, sludges, biosolids, and other suitable organic materials) isgrowing in importance and application across a variety of industries.Various Aries downdraft and fluidized bed gasifier systemimplementations may produce a hot carbonaceous solid residue that, whencooled, is commonly referred to as biochar (also referred to as “bio flyash” when recovered from a cyclone).

In illustrative examples, biochar may be favorable as a terrestrialcarbon sink, fertilizer, soil supplement, composting supplement, solids,water or gas filtration media for neutralization, odor control,purification and/or refinement, bioproduct manufacturing input,renewable building material manufacturing input, and solid catalystinput.

In an illustrative example, some implementations of Aries' prior artindirect biochar cooling designs may process and cool hot carbonaceoussolid gasification residue indirectly utilizing a water fed coolingscrew. In contrast, an Aries direct biochar cooling design in accordancewith the present disclosure may provide an alternative approach tocooling hot carbonaceous solid gasification residues utilizing directapplication of gas comprising steam or hydrocarbon gas to produce abiochar different in composition and physical format to biochar producedby indirect cooling. This resultant biochar produced based on coolingutilizing direct application of gas comprising steam or hydrocarbon gasmay be more suitable for certain product applications.

The present disclosure relates to a cost-effective means to cool hotbiochar produced through gasification using direct application of coolgases made up of H₂O or CH₄. In one aspect of the present disclosure,direct cooling of hot biochar with steam as the hot biochar exits thegasifier or cyclone creates an economical way to cool biochar whileenhancing the surface area of the biochar resulting in a byproduct thatis comparable to activated carbon. In another aspect of the presentdisclosure, direct cooling of hot biochar with hydrocarbon gas as thehot biochar exits the gasifier or cyclone creates an economical way tocool biochar while enhancing the high-quality carbon content of ourbiochar with nano tube type carbon formation on the biochar whileproducing a gas stream that can be filtered for high value chemical(specifically hydrogen) recovery.

In the Summary above and in this Detailed Description, and the Claimsbelow, and in the accompanying drawings, reference is made to particularfeatures of various implementations. It is to be understood that thedisclosure of particular features of various implementations in thisspecification is to be interpreted to include all possible combinationsof such particular features. For example, where a particular feature isdisclosed in the context of a particular aspect or implementation, or aparticular claim, that feature can also be used—to the extentpossible—in combination with and/or in the context of other aspects andimplementations, and in an implementation generally, whether or not suchembodiments are described with and whether or not such features arepresented as being a part of a described embodiment. Thus, the breadthand scope of the present disclosure should not be limited by any of theabove-described exemplary implementations.

While multiple implementations are disclosed, still otherimplementations will become apparent to those skilled in the art fromthis detailed description. Disclosed implementations may be capable ofmyriad modifications in various obvious aspects, all without departingfrom the spirit and scope of the disclosed implementations. Accordingly,the drawings and descriptions are to be regarded as illustrative innature and not restrictive.

It should be noted that the features illustrated in the drawings are notnecessarily drawn to scale, and features of one implementation may beemployed with other implementations as the skilled artisan wouldrecognize, even if not explicitly stated herein. Descriptions ofwell-known components and processing techniques may be omitted so as tonot unnecessarily obscure the implementation features.

In the present disclosure, various features may be described as beingoptional, for example, through the use of the verb “may;” or, throughthe use of any of the phrases: “in some implementations,” “in somedesigns,” “in various implementations,” “in various designs,” “in anillustrative example,” or, “for example.” For the sake of brevity andlegibility, the present disclosure does not explicitly recite each andevery permutation that may be obtained by choosing from the set ofoptional features. However, the present disclosure is to be interpretedas explicitly disclosing all such permutations. For example, a systemdescribed as having three optional features may be implemented in sevendifferent ways, namely with just one of the three possible features,with any two of the three possible features or with all three of thethree possible features.

In various implementations, elements described herein as coupled orconnected may have an effectual relationship realizable by a directconnection or indirectly with one or more other intervening elements.

In the present disclosure, the term “any” may be understood asdesignating any number of the respective elements, that is, asdesignating one, at least one, at least two, each or all of therespective elements. Similarly, the term “any” may be understood asdesignating any collection(s) of the respective elements, i.e. asdesignating one or more collections of the respective elements, acollection comprising one, at least one, at least two, each or all ofthe respective elements. The respective collections need not comprisethe same number of elements.

While various implementations have been disclosed and described indetail herein, it will be apparent to those skilled in the art thatvarious changes may be made to the disclosed configuration, operation,and form without departing from the spirit and scope thereof. Inparticular, it is noted that the respective implementation features,even those disclosed solely in combination with other implementationfeatures, may be combined in any configuration excepting those readilyapparent to the person skilled in the art as nonsensical. Likewise, useof the singular and plural is solely for the sake of illustration and isnot to be interpreted as limiting.

The Abstract is provided to comply with 37 C. F. R. § 1.72(b), to allowthe reader to quickly ascertain the nature of the technical disclosureand is submitted with the understanding that it will not be used tointerpret or limit the scope or meaning of the claims.

In the present disclosure, all descriptions where “comprising” is usedmay have as alternatives “consisting essentially of,” or “consistingof.” In the present disclosure, any method or apparatus implementationmay be devoid of one or more process steps or components. In the presentdisclosure, implementations employing negative limitations are expresslydisclosed and considered a part of this disclosure.

Certain terminology and derivations thereof may be used in the presentdisclosure for convenience in reference only and will not be limiting.For example, words such as “upward,” “downward,” “left,” and “right”would refer to directions in the drawings to which reference is madeunless otherwise stated. Similarly, words such as “inward” and “outward”would refer to directions toward and away from, respectively, thegeometric center of a device or area and designated parts thereof.References in the singular tense include the plural, and vice versa,unless otherwise noted.

Terms and phrases used in this document, and variations thereof, unlessotherwise expressly stated, should be construed as open ended as opposedto limiting. As examples of the foregoing: the term “including” shouldbe read as meaning “including, without limitation” or the like; the term“example” is used to provide exemplary instances of the item indiscussion, not an exhaustive or limiting list thereof; the terms “a” or“an” should be read as meaning “at least one,” “one or more” or thelike; and adjectives such as “conventional,” “traditional,” “normal,”“standard,” “known” and terms of similar meaning should not be construedas limiting the item described to a given time period or to an itemavailable as of a given time, but instead should be read to encompassconventional, traditional, normal, or standard technologies that may beavailable or known now or at any time in the future. Likewise, wherethis document refers to technologies that would be apparent or known toone of ordinary skill in the art, such technologies encompass thoseapparent or known to the skilled artisan now or at any time in thefuture.

The term “comprises” and grammatical equivalents thereof are used hereinto mean that other components, ingredients, steps, among others, areoptionally present. For example, an implementation “comprising” (or“which comprises”) components A, B and C can consist of (i.e., containonly) components A, B and C, or can contain not only components A, B,and C but also contain one or more other components.

Where reference is made herein to a method comprising two or moredefined steps, the defined steps can be carried out in any order orsimultaneously (except where the context excludes that possibility), andthe method can include one or more other steps which are carried outbefore any of the defined steps, between two of the defined steps, orafter all the defined steps (except where the context excludes thatpossibility).

The term “at least” followed by a number is used herein to denote thestart of a range beginning with that number (which may be a range havingan upper limit or no upper limit, depending on the variable beingdefined). For example, “at least 1” means 1 or more than 1. The term “atmost” followed by a number (which may be a range having 1 or 0 as itslower limit, or a range having no lower limit, depending upon thevariable being defined). For example, “at most 4” means 4 or less than4, and “at most 40%” means 40% or less than 40%. When, in thisspecification, a range is given as “(a first number) to (a secondnumber)” or “(a first number)-(a second number),” this means a rangewhose limit is the second number. For example, 25 to 100 mm means arange whose lower limit is 25 mm and upper limit is 100 mm.

Many suitable methods and corresponding materials to make each of theindividual parts of implementation apparatus are known in the art. Oneor more implementation part may be formed by machining, 3D printing(also known as “additive” manufacturing), CNC machined parts (also knownas “subtractive” manufacturing), and injection molding, as will beapparent to a person of ordinary skill in the art. Metals, wood,thermoplastic and thermosetting polymers, resins and elastomers as maybe described herein-above may be used. Many suitable materials are knownand available and can be selected and mixed depending on desiredstrength and flexibility, preferred manufacturing method and particularuse, as will be apparent to a person of ordinary skill in the art.

Any element in a claim herein that does not explicitly state “means for”performing a specified function, or “step for” performing a specificfunction, is not to be interpreted as a “means” or “step” clause asspecified in 35 U.S.C. § 112 (f). Specifically, any use of “step of” inthe claims herein is not intended to invoke the provisions of 35 U.S.C.§ 112 (f). Elements recited in means-plus-function format are intendedto be construed in accordance with 35 U.S.C. § 112 (f).

Recitation in a claim of the term “first” with respect to a feature orelement does not necessarily imply the existence of a second oradditional such feature or element.

The phrases “connected to,” “coupled to” and “in communication with”refer to any form of interaction between two or more entities, includingmechanical, electrical, magnetic, electromagnetic, fluid, and thermalinteraction. Two components may be functionally coupled to each othereven though they are not in direct contact with each other. The terms“abutting” or “in mechanical union” refer to items that are in directphysical contact with each other, although the items may not necessarilybe attached together.

The word “exemplary” is used herein to mean “serving as an example,instance, or illustration.” Any implementation described herein as“exemplary” is not necessarily to be construed as preferred over otherimplementations. While various aspects of the disclosure are presentedwith reference to drawings, the drawings are not necessarily drawn toscale unless specifically indicated.

Reference throughout this specification to “an implementation” or “theimplementation” means that a particular feature, structure, orcharacteristic described in connection with that implementation isincluded in at least one implementation. Thus, the quoted phrases, orvariations thereof, as recited throughout this specification are notnecessarily all referring to the same implementation.

Similarly, it should be appreciated that in the above description,various features are sometimes grouped together in a singleimplementation, Figure, or description thereof for the purpose ofstreamlining the disclosure. This method of disclosure, however, is notto be interpreted as reflecting an intention that any claim in this orany application claiming priority to this application require morefeatures than those expressly recited in that claim. Rather, as thefollowing claims reflect, inventive aspects may lie in a combination offewer than all features of any single foregoing disclosedimplementation. Thus, the claims following this Detailed Description arehereby expressly incorporated into this Detailed Description, with eachclaim standing on its own as a separate implementation. This disclosureis intended to be interpreted as including all permutations of theindependent claims with their dependent claims.

A system or method implementation in accordance with the presentdisclosure may be accomplished through the use of one or more computingdevices. As descried, for example, at least with reference to FIGS. 3,4, and 5, one of ordinary skill in the art would appreciate that anexemplary control system or algorithmic controller appropriate for usewith an implementation in accordance with the present application maygenerally include one or more of a Central processing Unit (CPU), RandomAccess Memory (RAM), a storage medium (e.g., hard disk drive, solidstate drive, flash memory, cloud storage), an operating system (OS), oneor more application software, a display element, one or morecommunications means, or one or more input/output devices/means.Examples of computing devices usable with implementations of the presentdisclosure include, but are not limited to, proprietary computingdevices, personal computers, mobile computing devices, tablet PCs,mini-PCs, servers, or any combination thereof. The term computing devicemay also describe two or more computing devices communicatively linkedin a manner as to distribute and share one or more resources, such asclustered computing devices and server banks/farms. One of ordinaryskill in the art would understand that any number of computing devicescould be used, and implementation of the present disclosure arecontemplated for use with any computing device.

In various implementations, communications means, data store(s),processor(s), or memory may interact with other components on thecomputing device, in order to effect the provisioning and display ofvarious functionalities associated with the system and method detailedherein. One of ordinary skill in the art would appreciate that there arenumerous configurations that could be utilized with implementations ofthe present disclosure, and implementations of the present disclosureare contemplated for use with any appropriate configuration.

According to an implementation of the present disclosure, thecommunications means of the system may be, for instance, any means forcommunicating data over one or more networks or to one or moreperipheral devices attached to the system. Appropriate communicationsmeans may include, but are not limited to, circuitry and control systemsfor providing wireless connections, wired connections, cellularconnections, data port connections, Bluetooth® connections, or anycombination thereof. One of ordinary skill in the art would appreciatethat there are numerous communications means that may be utilized withimplementations of the present disclosure, and implementations of thepresent disclosure are contemplated for use with any communicationsmeans.

Throughout this disclosure and elsewhere, block diagrams and flowchartillustrations depict methods, apparatuses (i.e., systems), and computerprogram products. Each element of the block diagrams and flowchartillustrations, as well as each respective combination of elements in theblock diagrams and flowchart illustrations, illustrates a function ofthe methods, apparatuses, and computer program products. Any and allsuch functions (“depicted functions”) can be implemented by computerprogram instructions; by special-purpose, hardware-based computersystems; by combinations of special purpose hardware and computerinstructions; by combinations of general purpose hardware and computerinstructions; and so on—any and all of which may be generally referredto herein as a “circuit,” “module,” or “system.”

While the foregoing drawings and description may set forth functionalaspects of the disclosed systems, no particular arrangement of softwarefor implementing these functional aspects should be inferred from thesedescriptions unless explicitly stated or otherwise clear from thecontext.

Each element in flowchart illustrations may depict a step, or group ofsteps, of a computer-implemented method. Further, each step may containone or more sub-steps. For the purpose of illustration, these steps (aswell as any and all other steps identified and described above) arepresented in order. It will be understood that an implementation mayinclude an alternate order of the steps adapted to a particularapplication of a technique disclosed herein. All such variations andmodifications are intended to fall within the scope of this disclosure.The depiction and description of steps in any particular order is notintended to exclude implementations having the steps in a differentorder, unless required by a particular application, explicitly stated,or otherwise clear from the context.

Traditionally, a computer program consists of a sequence ofcomputational instructions or program instructions. It will beappreciated that a programmable apparatus (that is, computing device)can receive such a computer program and, by processing the computationalinstructions thereof, produce a further technical effect.

A programmable apparatus may include one or more microprocessors,microcontrollers, embedded microcontrollers, programmable digital signalprocessors, programmable devices, programmable gate arrays, programmablearray logic, memory devices, application specific integrated circuits,or the like, which can be suitably employed or configured to processcomputer program instructions, execute computer logic, store computerdata, and so on. Throughout this disclosure and elsewhere a computer caninclude any and all suitable combinations of at least one generalpurpose computer, special-purpose computer, programmable data processingapparatus, processor, processor architecture, and so on.

It will be understood that a computer can include a computer-readablestorage medium and that this medium may be internal or external,removable, and replaceable, or fixed. It will also be understood that acomputer can include a Basic Input/Output System (BIOS), firmware, anoperating system, a database, or the like that can include, interfacewith, or support the software and hardware described herein.

Implementations of the system as described herein are not limited toapplications involving conventional computer programs or programmableapparatuses that run them. It is contemplated, for example, thatimplementations of the disclosure as claimed herein could include anoptical computer, quantum computer, analog computer, or the like.

Regardless of the type of computer program or computer involved, acomputer program can be loaded onto a computer to produce a particularmachine that can perform any and all of the depicted functions. Thisparticular machine provides a means for carrying out any and all of thedepicted functions.

Any combination of one or more computer readable medium(s) may beutilized. The computer readable medium may be a computer readable signalmedium or a computer readable storage medium. A computer readablestorage medium may be, for example, but not limited to, an electronic,magnetic, optical, electromagnetic, infrared, or semiconductor system,apparatus, or device, or any suitable combination of the foregoing. Morespecific examples (a non-exhaustive list) of the computer readablestorage medium would include the following: an electrical connectionhaving one or more wires, a portable computer diskette, a hard disk, arandom access memory (RAM), a read-only memory (ROM), an erasableprogrammable read-only memory (EPROM or Flash memory), an optical fiber,a portable compact disc read-only memory (CD-ROM), an optical storagedevice, a magnetic storage device, or any suitable combination of theforegoing. In the context of this document, a computer readable storagemedium may be any tangible medium that can contain or store a programfor use by or in connection with an instruction execution system,apparatus, or device.

Computer program instructions can be stored in a computer-readablememory capable of directing a computer or other programmable dataprocessing apparatus to function in a particular manner. Theinstructions stored in the computer-readable memory constitute anarticle of manufacture including computer-readable instructions forimplementing any and all of the depicted functions.

A computer readable signal medium may include a propagated data signalwith computer readable program code encoded therein, for example, inbaseband or as part of a carrier wave. Such a propagated signal may takeany of a variety of forms, including, but not limited to,electro-magnetic, optical, or any suitable combination thereof. Acomputer readable signal medium may be any computer readable medium thatis not a computer readable storage medium and that can communicate,propagate, or transport a program for use by or in connection with aninstruction execution system, apparatus, or device.

Program code encoded by a computer readable medium may be transmittedusing any appropriate medium, including but not limited to wireless,wireline, optical fiber cable, RF, etc., or any suitable combination ofthe foregoing.

The elements depicted in flowchart illustrations and block diagramsthroughout the figures imply logical boundaries between the elements.However, according to software or hardware engineering practices, thedepicted elements and the functions thereof may be implemented as partsof a monolithic software structure, as standalone software modules, oras modules that employ external routines, code, services, and so forth,or any combination of these. All such implementations are within thescope of the present disclosure.

Unless explicitly stated or otherwise clear from the context, the verbs“execute” and “process” are used interchangeably to indicate execute,process, interpret, compile, assemble, link, load, any and allcombinations of the foregoing, or the like. Therefore, implementationsthat execute or process computer program instructions,computer-executable code, or the like can suitably act upon theinstructions or code in any and all of the ways just described.

The functions and operations presented herein are not inherently relatedto any particular computer or other apparatus. Various general-purposesystems may also be used with programs in accordance with the teachingsherein, or it may prove convenient to construct more specializedapparatus to perform the required method steps. The required structurefor a variety of these systems will be apparent to those of skill in theart, along with equivalent variations. In addition, implementations ofthe disclosure are not described with reference to any particularprogramming language. It is appreciated that a variety of programminglanguages may be used to implement the present teachings as describedherein, and any references to specific languages are provided fordisclosure of enablement and best mode of implementations of thedisclosure. Implementations of the disclosure are well suited to a widevariety of computer network systems over numerous topologies. Withinthis field, the configuration and management of large networks includestorage devices and computers that are communicatively coupled todissimilar computers and storage devices over a network, such as theInternet.

A number of implementations have been described. Nevertheless, it willbe understood that various modifications may be made. For example, thesteps of the disclosed techniques may be performed in a differentsequence, components of the disclosed systems may be combined in adifferent manner, or the components may be supplemented with othercomponents. Such modifications are to be considered as included in thefollowing claims unless the claims by their language expressly stateotherwise. Variations described for exemplary implementations of thepresent disclosure may be realized in any combination desirable for eachapplication. Accordingly, other implementations are contemplated, withinthe scope of the following claims.

What is claimed is:
 1. A method comprising: heating biochar retainedwithin a processing chamber, using a heat source thermally coupled withthe processing chamber; and in response to determining the biocharretained within the processing chamber heated to at least apredetermined temperature: discharging the heated biochar into a coolingchamber; injecting cool gas into the cooling chamber; applying the coolgas directly to the biochar retained within the cooling chamber; and inresponse to determining the biochar retained within the cooling chambercooled to a predetermined temperature, discharging the cooled biocharfrom the cooling chamber; wherein the method further comprises receivingthe biochar from a gasifier fluidly coupled with the processing chamberinto the processing chamber, and retaining the biochar within theprocessing chamber.
 2. The method of claim 1, wherein the method furthercomprises receiving biochar into the processing chamber.
 3. The methodof claim 1, wherein the gasifier further comprises a downdraft gasifier.4. The method of claim 1, wherein the gasifier further comprises afluidized bed gasifier.
 5. The method of claim 1, wherein the heatsource further comprises a heating element.
 6. The method of claim 5,wherein the heat source further comprises process heat, and wherein themethod further comprises: in response to determining the process heat isat least a predetermined minimum temperature, deactivating the heatingelement.
 7. The method of claim 1, wherein discharging the heatedbiochar into the cooling chamber further comprises fluidly coupling theprocessing chamber to the cooling chamber.
 8. The method of claim 1,wherein the method further comprises retaining the biochar within theprocessing chamber for at least a predetermined time period.
 9. Themethod of claim 1, wherein the method further comprises releasing thegas from the cooling chamber into a particulate filter fluidly coupledwith the cooling chamber.
 10. The method of claim 9, wherein the methodfurther comprises recovering carbon dioxide from a CO₂ removal filterfluidly coupled with the particulate filter.
 11. The method of claim 9,wherein the method further comprises recovering hydrogen from an H₂removal filter fluidly coupled with the particulate filter.
 12. Themethod of claim 11, wherein the method further comprises recycling tailgas as cooling gas supplied to the cooling chamber through a tail gasrecycle loop fluidly coupled with the H₂ removal filter and the coolingchamber.
 13. The method of claim 9, wherein the method further comprisesheating the biochar retained within the processing chamber using processheat comprising heat generated by a thermal oxidizer from tail gas,wherein the thermal oxidizer is thermally coupled with the processingchamber.
 14. The method of claim 13, wherein the method furthercomprises supplying the tail gas to the thermal oxidizer from an H₂removal filter fluidly coupled with the particulate filter.
 15. Themethod of claim 1, wherein receiving biochar from the gasifier furthercomprises receiving biochar from a plurality of gasifiers.
 16. Themethod of claim 15, wherein more than one gasifier of the plurality ofgasifiers is fluidly coupled with the processing chamber.
 17. The methodof claim 13, wherein the heat source further comprises a heatingelement, and wherein the method further comprises repeating the methodwith the heating element deactivated.
 18. The method of claim 13,wherein the method further comprises releasing the biochar from thecooling chamber into a biochar recovery system.